Service Manual Datsun Pick-Up 1977

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MANUAL

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ENCE fEFEf

INDEX

FOREWORD prepared for the purpose of assisting service personnel of dealers fu providing effective service and maintenance of the

This service manual has been authorized NISSAN DATSUN 1977 Datsun Pick up

Since proper maintenance and service

la1 should be inan

owners this

carefuny

fu

kept

fu

absolutely essential handy place for ready

are

a

the Datsun

satisfying

reference and should be

studied la1 fucludes man

This

procedures for

ma futenance

minor

1justrnents ac

service

operations

remowl and installation and for disassembly and assembly of components

operations require

Some of these service

effectiveperfonnance The

special

As you

tools are

read

occasionally

ofservice

corne across

gives the beginning

At the

of each

on

and Qr

damage

in

for

CAUTION

supplemental

of steps that must

warns

to some part of your DATSUN

to

user

of each individual section is

which each

you will

this service manual

the first page enables the

on

a

quickly

table of contents which

An index is

major subject begins

locate the

placed

at the

within the section

major subject

All information illustrations and

specifications

contained in this manual

latest product information available at the time of publication

model differs from the

especially designed

CAUTION A NOTE is

or

particular procedure

beginning

page number

procedures

headed NOTE

paragraphs

prevent personal injury

desired section

Tools

section

the maintenance

Reference Index

The Quick

SE

in the

infortl1ation that is important to B be fonowed to

Special

operations

presented

through

the use of

specifications

approval

are

based

on

the

If YOUT DATSUN

consult your NlSSAN

contained in this manual

DATSUN dealer for information

for alteratiohat any time of specifications and methods

Rights

liability

for any

la1 in man

effecting

M9tor

Co

maintenance

or

or

reserved

property damage occasioned by the

repair

of

your Datsun is in

no

by

anyone

using

a

Nissan must fust

service

procedure

completely satisfy

vehicle s safety wi11be jeopardized

by

or

N1SSAN

by

MOTOR CO

LTD

specifically

himself that neither his

Nissan

safety

w

nor

the

the service method selected MOTOR TOKYO

1976

of this service

way assumed

tool which is not

NISSAN

@

use

Ltd

Accordingly mended

personal injury

are

Printed in Japan

CO

JAPAN

LTD

I

SECTION GI

GENERAL INFORMATION

DATSUN PICK UP MODEL 620 SERIES

GENERAL INFORMATION

I NISSAN I NISSAN MOTOR CO TOKYO

LTD JAPAN

GI

3

General Informa ion

Fig GI I Standord wheelbase model

Fig GI 2 Delux Cob

GI 2

L

General Information

GENERAL INFORMATION CONTENTS GI B

MOOEL VARIATION

GI 3

APPROXIMATE

IDENTIFICATION NUMBERS

GI 5

RECOMMENDED FUEL

GI B

LIFTING

GI B

RECOMMENDED

GI 8

POINTS AND TOWING

REFILL CAPACITIES

LUBRICANTS

LIFTING POINTS

GI B

RECOMMENDED SAE VISCOSITY

SUPPORTABLE POINTS

GI 7

NUMBER

TOWING

GI 7

LUBRICANT

TIE

GI 7

DOWN

GI 8 GI g

SPECIFICATIONS

MODEL VARIATION Differential Destination

Model

Class

Engine

Transmission

carrier model

and gear ratio

Standard wheelbase

S E Ol 0 0

u

E

Long

0

E

wheelbase 0

8 a

Ol

0 0

u

Ol u

Deluxe Cab

I I

HL620TUV

F4W7lB

HL620FTUV

FS5W71 B

I

HL620KTUV

3N7lB

I I I I

HLG620TUV

F4W7lB

HLG620FTUV

FS5W71B

HLG620KTUV

3N7lB

KHL620TUV

F4W7lB

I

KHL620FTUV

FS5W7lB Hl90

KHL620KTUV

L20B

3N7lB

i u

0 Standard

HL620TU

F4W71 B

HL620FTU

FS5W7l B

HL620KTU

3N7lB

wheelbase U

S

0 0

E 0

0

Long

8

wheelbase u

Q 0

0

Z

Q

I I IHLG620KTU HLG620TU

F4W7lB

HLG620FTU

FS5W7lB

KHL620TU

F4W71B

KHL620FTU

FS5W7l B

KHL620KTU

3N7lB

3N7lB

Deluxe

Cab

I

GI 3

375 4

Pay load kg Ob

500

100

r

General Information

Differential Destination

Class

Model

Transmission

Engine

carrier model

Pay load

lb kg

and gear ratio

Standard wheelbase

HL620TUN

F4W71B

HL620KTUN

3N71B

0

Long Canada

wheelbase

2

0

Deluxe

HLG620TUN

E

Z

Cab

F4W7IB

I

HLG620KTUN

I I

KHL620TUN

F4W71B

KHL620FTUN

FS5W7IB

L20B

3N71B

I KHL620KTUN

Hl90 375 4

3N7J B

Model identification

KHLG620KTUV

I

I

LU

Destined for

V

California model

N

Canada model

T

Floor shift vehicle

K

Automatic transmission

F

5

Note 0

means no

manual transmission

4 speed manual transmission

0

I

speed

s A and Canada U

G

Long wheelbase

o

Standard wheelbase and Deluxe Cab

H

Equipped

K

Deluxe Cab

identification

4 GI

with L20B engine

500

100 1

General Informa tion

IDENTIFICATION NUMBERS

Engine serllii The

The unit and vehicle numbers

are

stamped and registered at the factory The engine and vehicle identifica tion numbers are used on legal docu These numbers

ments

factory

are

communications

used

for

such

as

engine

number serial

number

tW

is

the right hand side of the

stamped cylinder block on

I

L20B XXXXXX

1

I

Reports Warranty Claims Service Journals and other informa

I

Serial number

j

Technical

Engine model

tion

Vehicle IdentHication plate The

il SP031

Fig GI 7 M V S S certification

k

label location

vehicle identification plate is

located at the hood

ledge

in the

engine

compartment Vehicle emission control Information

label

The vehicle emission control infor mation label is stuck the hood

on

the

insicre

of

panel

SP029

GI 3

Fig

Vehicle identification plat location

Vehicle serial number Color code number The vehicle serial number is stamp ed

on

the upper face of the right side

member The number is identified the

follQwing

flgUres

as

a

by

The stuck

color

on

code

the radiator

number

SP076

label is

Fig GI B Vehicle emia ion control information label location

support

serial

number Manual transmission number

HL620 XXXXXX

I

The transmission serial number is stamped on the front upper face of

Serial number

transmission

case

Vehicle model

Number system x X XXXXX GI326

Fig

I

Serial number

01 6 Color code number label location

monthly Month of

j

manufacture e

M VS S

c

rtlflcatlon label

G1268

Fig

4 Vehicle serial number GI location

The M V S S

certification label is

located at the driver side lock

Gl 5

pillar

2

9 XY Z

Line code of manufacture

iGetneiraolnfonrml Apply parking brake block

rear

vehicle is

firmly and

wheels if the front of the

to

be raised

Notes a

YeDow mark

Never

get under the vehicle while it is supported only by the jack Always use safety stands to support frame

WHOSO

when you have to get beneath the vehicle b In no event should the jack be location

When

place

number The attached

a

jacking up the jack under

screw

about 520

transmission serial number is the

to

case

the

applied to any points except following specified portions

Fig GI 9 Manual trammiuion number


axle

or rear

front

side

at

rear

of

front axle center

Garage Jack

right hand side of

transmission case

Note

When carrying out operntions

with

Numbering system

a

garage

jack

be

sure

to

support the vehicle withstands in a safe manner

X XXXXX

I

Serial number

jacking up the front end apply garage jack to front cross When

monthly Month of

member

manufacture I 2

t

ogai

over stroke

side frame

5 in 20

nun

Fig GI 13 Warning

WT012

9 X Y Z

When Fig GI

ll

Front lifting point

or

portion of

center

sus

pension member

apply

jacking

the jack to

the

up

rear

end

rear axle case

last figure of year of

manufacture

When jacking up the rear side

place

jack under rear axle side of rear spring

close

a screw

to the

case

J r

uc

I

GI075

n9 Fig GI 14 Front lifting point

AT344 WH077

Fig 01 10 Automatic trammision number location

Fig GI 12 Reor lifting point

LIFTING POINTS AND TOWING

Notes a

LIFTING POINTS

When the

the

screw

maximum

Screw jack

yellow mark appean

on

jack it indicates permissible height

the Do

not jack up further

Before using the follows

jack proceed

a

b When the jack is at lower llinit do not add

large

force downward

6 GI

GI076

Fig GI 15 Rear lifting point

General Information To tow another

SUPPORTABLE POINTS

rope to The front

supportable points

under

rear

connect

t1ie

Before towing make

are

rear axle case

a

rope should not be con nected to any position other than A

as

the trans

sure

mission is in neutral gear

Notes

supportable points

Manual transmission

leaf spring shackle

are

under frame side member The

rear

car

towing

described above

b Avoid

applying

towing

rope

as

load

suddenly

to a

it may cause dam

age

If

the

axle

rear

the

inoperative

towed with its

ground

the

or

transmission is

or

vehicle

should

be

wheels off the

rear

propeller

shaft must be

l1oved re Automatic transmission When the vehicle is towed wheels

rear

make N

mission is in

MPH

distance of Hi kin 6 miles axle

or

if the

exceed

speed

and

a

Ifthe rear

inoperative

transmission is

its

trans

position

Neutral

Don t exceed 30 km h 20

Fig GI 16 Front supportable points

on

the

sure

or

the above condi

tions the vehicle must be towed with

ground

its rear wheels off the

propeller

the

or

shaft must be removed

WH131

Fig Gl 18 Fronttowing point

Note

When the vehicle is towed with

its front wheels on the

steering

maintain

v

the

ground

wheel shouId be secured to a

straight

ahead

position

TIE DOWN

GI078

Fig GI 17 Rear supportable points

The front two tie down hooks are

located under the 1st crosSInember The hook is available

TOWING When

the vehicle is to be

hook

towed

connect a rope securely to the hook under the 1st CrosSIn ember

Before towing make brake is released

sure

rear

spring shackle be used

forward

the

For

down tie

also used

parking Fig 01 19 Rear towing point

GI 7

as a

as

the

a

towing

rear

leaf

lIDs point is

towing point

General Information

APPROXIMATE REFILL CAPACITIES

I I

45

ManUal transmission

I

8

0J

Automatic tr

I

7

8J

Fuel tank

Cooling system with heater

Engine lubrication system

Manual transmission

I I

smission

us

8Y qt

6Jiqt

I

4Ji qt

3

without oil f1lter

I

3

8J

I

1 7J

I I I

5

speed transmission

I I

2

s J 5

I

box

4

I

10 J

qt

qt

3Xqt

ql

3Xpl

3

4Y pt

3Mpt

5Uqt

4Uqt

pt

pt

I

33J 0

I

Differential carrier

0

9 Ji gal 7

3J

I

measure

8Jiqt

4

speed transmission

Imper

I I

I

4

measure

IUi gal

J

with oil f1lter


Steering gear

Uter

2M pI

pI

I

pt

RECOMMENDED FUEL Use

an

gasoline with

unleaded a

or

low lead

of

91

RON

Research

Octane

For California models Nuniber

minimum octane rating

use

only unleaded gasoline

catalytic tion

RECOMMENDED LUBRICANTS RECOMMENDED SAE VISCOSITY NUMBER C

ENGINE on IIO 10Vt4ll 10Wf 12O

I

ao

40

2

ICWII

J SAE 5W 20 oils ate not lecom mended for sustained high speed

drivin GEAR On

I J

w

c

30

20

0

20

40

60

Temperature Range Anticipated Next Oil Change OF

8 GI

80

100

Before

converter

to

from

protect the contamina

General Information

LUBRICANT SPECIFICATIONS

Specifications

Item

SAE Classification Gasoline engine oil

SD

or

SE

Remarks Furthermore refer to SAE recommended viscosity table See Poge GI B

Transmission and

0

API

4 GL

steering Differential Automatic

TIM fluid

Multipurpose

grea

Brake and clutch fluid

API

GL S

Type

DEXRON lithium soap base

NLGI2 DOT 3

Permanent anti freeze

Antifreeze

Ethylene glycol ba

GI 9

e

SECTION ET

ENGINE TUNE UP



LTD JAPAN

ENGINE TUNE UP

ET 2

BASIC MECHANICAL SySTEM

ET 7

IGNITION AND FUEL SYSTEM

ET

EMISSION CONTROL SYSTEM

ET 13

SERVICE DATA AND SPECIFICATIONS

ET 25

TROUBLE DIAGNOSES AND CORRECTIONS

H 27

9

Engine

Tune up

ENGINE TUNE UP CONTENTS LOCATION OF EMISSION

CONTROL

EMISSION CONTROL SYSTEM PIPING

SYSTEM COMPONENTS

lNon California models

INon California models

ET 2


ET 3

EMISSION CONTROL DEVICES

LOCATION OF EMISSION CONTROL SYSTEM

COMPONENTS

California models

California models

4 ET

ET 5 ET 6

LOCATION OF EMISSION CONTROL SYSTEM COMPONENTS Non California models

6

7

@

9

I 2 3 4

5

Thermal vacuum valve Check valve Air gallery pipe Auto choke

6

Automatic temperature control air cleaner Anti Backfire valve A B valve

7

Bo05t Controlled

8

Deceleration Device P C V valve

9

Air

10

j D

relief valve

E

12

G R control valve Air pump air cleaner Carbon canister

13

Air

14

Spark delay

11

8C D

pump valve

AfT models

ET365

Fig ET l Location of emaion control sy tern component Non California mod I

ET 2

Engine

Tune

up

LOCATION OF EMISSION CONTROL SYSTEM COMPONENTS California models

8

7

8

cv

@

valve

1

Thennal

2

Check valve

3

Altitude compensator in air cleaner

4

Air

vacuum

gallery pipe

5

qj

choke Auto

6

Automatic temperature control air cleaner

7

Anti Backfire valve

8

Boost Controlled Deceleration Device B C D O

9

P C V valve

A

B valve

relief valve E G R control valve

10

Air

11 12

6 C D D control valve and

solenoid

valve relief valve

13

Emergency air

14 IS

Air pump air cleaner Carbon canister

16

Air control valve

17

Air pump

ET366

Fig ET 2 Location 01 emiuion control sydem component California mod a

ET3

r Engine

Tune up


1 2

3 4 5 6

Vacuum tube to distributor yellow Vacuum tube to carbon canister yeUow Vacuum tube to thermaJ vaCuum valve white Vacuum tube Vacuum tube to carburetor yellow Thermal vacuum valve to E G R control valve

white

7

Vacuum tube to carburetor white

8

A

9

Vacuum tube

10 11

Non California models

B valve to

vacuum to

connector

green

carbon canister yellow

S D V to distributor yellow Vacuum tube to S D V yellow ET367

Fig ET 3 Emi8ion

4 ET

stem piping control8


Engine

Tune up


1 2

3

Vacuum tube to distributor yellow Vacuum tube to carbon canister yellow Thermal Vacuum valve to E G R control valve

4

California models

white

Vacuum

tube to thermal

vacuum

valve

white 5

Vacuum tube

6

Vacuum tube to

7

Vacuum

8

Vacuum tube to

9

Air

carburetor yellow hose connector to intake manifold

green carburetor white valve to vacuum hose

tro

con

connector

green

10

A B

to vacuum

11

D C D D

12

B

valve

to

connector

control valve

green

white

C D D control valve to intake manifold

green 13

Vacuum hose connector to E A R control valve

14

green

D

C D D control valve to air pump air cleaner ET368

Fig ET 4 Emission control system piping California models ET5

lIIIII mJ Cr l l c Jl

x

X

X

X

I

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X

X

alvc

X

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vacum exhausl valve

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X

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Thermal AlP valve valve valve VUI lD fThermal ITon device pump

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Engine

Tune up

BASIC MECHANICAL SYSTEM CONTENTS ADJUSTING

INTAKE AND EXHAUST

VALVE CLEARANCE

ET 7

CHECKING AND ADJUSTING DRIVE BELT

ET B

AND CONNECTIONS

ET B

INSPECTION OF

ET 7

RETIGHTENING CYLINDER

PERMANENT ANTI FREEZE COOLANT CHECKING COOLING SYSTEM HOSES

COOLING

HEAD BOLTS

CHECKING

MANIFOLD NUTS AND CARBURETOR

RADIATOR CAP PRESSURE

TEST

VACUUM

FITTINGS

HOSES

SECURING NUTS

ET7

AND CONNECTIONS

CHECKING ENGINE OIL

ET B

CHECKING ENGINE

REPLACING OIL FILTER

ET B

COMPRESSION

CHANGING

ET B

TEST RESULT

ENGINE

COOLANT

ADJUSTING INTAKE AND EXHAUST VALVE CLEARANCE Note

bolts

adjust

intake

and exhaust

1

Check for

cracks

or

ET B

ET B ET 9

COMPRESSION

ET 9

TEST

PRESSURE

CHECKING AND ADJUSTING DRIVE BELT

After tightening cylinder head

ET B

SYSTEM

ET 9

2 to

Normal drive belt deflection is 8 12

mm

0 315 to 0 472 in

moderate thumb

pressure

is

when

applied

midway between pulleys

damage Re

place if necessary

valve clearances clearance

Valve

is

adjustment

impossible when the engine is in oper Compressor pulley

ation 1

Loosen

pivot

turn

pivot locking screw

until the

nu t

and 8 to 12

specified

mm

0 315

Idler

clearance is obtained while cold

up

engine

for

at

pulley

8 to 12

and recheck the clearance Warm

in

472 0

Water pump

Using service tool tighten pivot locking nut securely after adjustment 2

to

mm

pulley 0 315 to 0 472 in

least

several minutes and stop it Measure valve clearance while hot If out of

specifications adjust

Air

Unit

mm

pump pulley

in Alternator

Intake

0 20 0 008

Exhaust

0 25

Intake

0 25 OmO

Cold 0 010 AC456

Fig ET 6 Driue belt tension

Wann

I

Exhaust

30 0

0 012

RETIGHTENING CYLINDER HEAD BOLTS MANIFOLD NUTS AND

CARBURETOR SECURING NUTS

Tightening torque Cylinder head bolts 1st turn 4 0

kg

6 0 kg

ET009

Fig ET 5 Adjusting valve clearance

Refer to

the

following tightening

torque specifications ET 7

29 ft Ib

m

43 ft Ib

3rd turn 5 to 6

STl 064000 I

m

2nd turn

5 8

kg m

47 to 61 ft lb

r Tune up

Engine ManifolJ

I 2 to 16

8 7

5 0

10 kg

to

Do not overtighten oil

Note

Carburelor nuls 3 6

tighlen

filter

by hand

m

kg

oil

installing

I 6 ft lb

to

to

When

2

nuts

lest

m

leakage

should

flIt

occur

7 2 fl tb

CHANGING ENGINE

Fig

fJ ET

l rod ioto Teltill

cop

COOLANT COOLNG SYSTEM PRESSURE TEST

PERMANENT ANTI FREEZE COOLANT Fig ET 7 Tightening s quence

Permanent anti freeze coolant is

an

base producl conlain

ethylene glycol ing chemical inhibilors 10 protect the cooling system against corrosion The anti freeze

CHECKING ENGINE

any

OIL Check if oil is diluled with water gasoline Drain and refill oil if

or

does

glycerine ethyl or

contain

not

methyl alcohol

to the

psi of a

lesler to

Water

temperaturethennoslat

Notes

the

of

cooling

water Isolate the cause

and take corrective

b An oil with extremely low viscosity indicates dilution with gasoline

capacity

7 U US qt

fImp qt 6

8 0 liters 8 fUS qt 7

Imp

qt

cooling system The anti freeze must not be mixed

with other products This coolant can be used

measure

leakage

With heater

flows freely transfers heat effi ciently and will not clog passages in

milky oil indicates the presence

detect any

means

7 4 liters

It

A

cooling system by

Without heater

It will not evaporate or boil away and can be used with either high or low

necessary

a

With radiator cap removed apply 1 6 kg cm2 23 reference pressure

out

through

the seasons of the year

Whenever coolant is

changed

the

cooling syslem should be flushed and 2

Check

specified

oil

level

level

If below

the

raise it up 10 the H

refilled with Check

a

new

coolant

the level See

the instruc

lions furnished by the manufacturer for the mixture ratio of anti freeze 10

level

Engine oil capacity including oil filter

water

Maximum H leven 3 liters 4 4

MUS qt 3 Y Imp qt

Minimum L

level

3 liters US qt 2 U 3 f

Imp ql

CHECKING COOLING SYSTEM HOSES

FITTINGS HOSES AND CONNECTIONS

AND CONNECTIONS Check hoses and connections

tighten

REPLACING OIL

CHECKING VACUUM

or

or

replace

fittings

for loose

deterioration

Re

if necessary

FILTER be

a

cartridge

removed

using

type and

Oil

Filter

Check for oil leaks past gasketed flange If leakage is found retighten I

ening mter

is

no

as an

vacuum

or

hoses

replace can

if

neces

be identified

White line

INSPECTION OF RADIATOR CAP

Vacuwn tube to carburetor E G R

Wrench STI9320000

just enough

Retighten

sary All

by colors

The oil mter is can

Check the condition of filtings and hoses

to

stop leakage Ifretight

longer

assembly

effective

replace

Apply kg cm2 means

reference 13

of

a

psi1 cap

09

pressure

to radiator cap tester

satisfactory Replace

to

cap

see

by

if it is

assembly

if

Tube Vacuum tube to thermal

Thennal

vacuum

control valve

necessary 8 ET

vacuum

valve valve to E G R

Tune up

Engine

Different

Yellow line

compression in two or cylinders usually indicates an improperly seated valve or broken piston ring

I

Spark delay valve to distributor Spark delay valve to vacuum tube

more

Distributor to vacuum tube

9

compression in cylinders can result from worn piston rings This condition may usually be accompanied by excessive fuel consumption

Vacuum tube to carburetor Vacuum tube to canister Green line Anti backfire valve to intake mani

ET010

fold

TEST RESULT Fig ET

Air control valve to emergency air

Teding compression

10

pressure

relief valve Intake

manifold to

vacuum

If compression is low

Depress accelerator pedal

5

Intake manifold to canister

to open

throttle and choke valves

CHECKING ENGINE COMPRESSION

Note

Do not

Start

6

engine

as

I

quickly

as

7

TEST

2 3

2

Compression pressure kg cm2 psi at rpm

12 0

9 0

Properly attach tester to spark plug

being

a

compression cylinder

hole in

8

oil increases the

com

the chances are that

If pressure stays low is that valve is sticking

probable or

seating

If cylinder compression in any adjacent cylinders is low and if adding oil does not help the compres sian there is leakage past the gasket 3

350

171

two

128

350

Cylinder compression

in

Should not be less than 80

surface

cylinders

of highest

Oil and water in combustion cham bers can result from

reading

tested

more

or

small quantity

improperly

Minimum

valve connector

one

cause

Standard

engine sufficiently Disconnect all spark plugs Disconnect anti dieseling solenoid

Warm up

4

If adding

pression pressure rings are faulty

pos

sible

PRESSURE

COMPRESSION

a

pression

pedal

pump

in

cylinders pour of engine oil into cylinders through the spark plug holes and retest com

hose

connector

I

Low

leakage

IGNITION AND FUEL SYSTEM CONTENTS ET

CHECKING BATTERY CHECKING AND ADJUSTING

CHECKING DISTRIBUTOR CAP

ET 10

ADJUSTING IGNITION TIMING CHECKING AND REPLACING SPARK PLUG CHECKING DISTRIBUTOR

ADJUSTING

ETlO

AND MIXTURE

ET 11

IGNITION WIRING

ET 11

Unscrew

inspect Check

tery cell

electrolyte

level in each bat

each

filler

cap

and

fluid level If the fluid is low

approximately

10 to 20

H9

mm

ET 12

ET13

linkage

FUEL

add distilled water to bring the level up

ET 12 RETURN SPRING

LINES

pipings connections

REPLACING

I

ET 11

CAP

FUEL

CHECKING Hoses

RPM

CHOKE MECHANISM

Choke plate and

ET11

DISTRIBUTOR

LIMITER

CHECKING

ET 10

GAP lCalifornia models

IDLE

RATIO

CHECKING CARBURETOR

ETlO

POINTS lNon California models

ET 11

CARBURETOR

ET10

OPERATING

CHECKING BATTERY

ET 11

CONDENSER

IDLE

PARTS AND IGNITION WIRING

BREAKER

ROTOR

AND CONDENSER

TIMING

AI R

9

IGNITION

39 0

etc

ET 13 ET 13

FILTER

to 0 79 in

above the

plates

Do not

overfill 2

Measure

the

battery electrolyte

specific gravity

of

p

Engine r

Rinse

water

pressed clean

air

to

off and dry with com Top of battery must be

prevent

terminals

tween

Tune up

terminal to

current

and

leakage

from

down hold

be

positive

on

accumulation of acid and dirt

ET002

Checking specific gravity ofbottery electrolyre

Fig E1 11

Clean top of battery and terminals with a solution of bakin soda and

of

top If l l ry the

may ca u iCbli

t

g I rj

material covering connector

straps and corrosion of straps After tightening terminals coat them with vaseline

petrolatum from corrosion Full

Pennissible

to

REPLACING SPARK PLUG I

clamp

In addition to current leakage pro

longed

CHECKING ANb

protect them

Remove and clean

2

Inspect insulator

for cracks

or

3

Check

both center and ground

electrodes If they are excessively place with new spark plugs

Spark plug

4

worn

re

gap

Breaker points type 0 8 to 0 9 mm

charge

at 200C

in a sand

chips

value

value

plugs

blast cleaner

0 031 to

680F

035 in 0

Transistor ignition type 10 to 1 mm

Frigid

Over 1 22

climates

Tropical

climates

Other climates

lOver lOver

1 28

0 039 to 0 043 in

Tightening

1 18

123

120

26 1

torq kg m

5 to 2 0 1

11 to A4 ft lb

CHECKING AND

ADJUSTING IGN ITIONTIMiNG IGNITION

ADIUSTING TIMING

Fig ET 14 Checking spark plug point Check spark plugs and distributor breaker points for condition I

Thoroughly

2

remove

gap

dirt and dust

from timing mark on crank pulley and timing indicator on front cover

engine sufficiently Imtalla timing light on No

CHECK I

DISTRIBUTOR OPERATING PARTS

Warin up

3

4

cylinder spark plug wire

and install

I

AND 1 WIRING

a

tachometer 5

Set idling

spero toapproxintate

BREAKER

Check

ignition

timing light if it

is

timing

with

a

specified value

1

oo

Fig ET 13 Checking ignition timing

be moved by hand

Adjust ignition timing

0 3

to

speci

that timing is

the

distributor

breaker

ai1d

correc

120 750 rpm

Non California

models

100 750 rpIll California models Automatic transmission

120 650 rpin in

0 position ET 10

Replace are

if necessary Make

properly aligned

sure

and that

wear

they point

dwell and gap are correct Clean and

Ignition timing Manual transmission

Lock distributor setscrew sure

ET169

distribu

fied value

make

Check

points for abnonnal pitting and

it as follows

Loosen setscrew until

tor can

2

adjust

POINTS


I Ifnecessary

lrI9N

y

750 rpm 6

G

apply

distributor grease to the

carn

lobes Note

00 not

apply grease excessively

Point gap 0 45 to

55 0

mm

Om8 to 0022 in Owell angle 49 to 55 degrees

Tune up

Engine

cap and check cable resistance only If resistance is still more than 30 000

ped

ohms replace cable assembly

Be

check should be per

models

fonned in the sure

position

D

parking

to engage

to lock both front and

brake and

rear

wheels

with wheel chocks b

brake your foot down on the

Keep

pedal while depressing the accelera tor pedal Otherwise vehicle surges forward dangerously

EE322

Fig ET 15 Checking diltribu tor Notes

point gap EF125

AIR GAP

Gap

refer to the

in Section EE

topic

Air

page EE 29

Check centrifugal advance unit for tion

If it

improper operating properly be due to a sticky opera

or

is not

the

problem may spring or excessively worn parts This operation needs a distributor tester For inspection procedures and ref data refer to relative topic erence under Distributor in Section EE

If vacuum advance mechanism does

properly

not

check

operate

Check

1

leakage retighten 2

at or

Check

inlet for signs of If necessary

replace vacuum

diaphragm

for air

leak If necessary

replace diaphragm

Note

This

be

to

per

surfaces

of all

fully

not

are

parts of

Burned

replacing

minal

When be

before

pushing

sure

they

rubber

and

CONDENSER Clean

wire

2

cap

for

lead

if necessary

Check

condenser

with

a

con

ance

to

check resist

cables from spark proper

adapter

spark plug

plugs

and install

between

Remove

and secondary cables

cable

20 0

a

Check resistance of

one

cable

at

a

time

Connect ohmmeter between

spark

plug adapter and corresponding elec is more trade inside cap If resistance than 30 000 ohms remove cable from

adjustment requires especially for

mixture a

CO meter

When

California models

adjust idle

mixture

preparing

to

is essential to

it

have the meter thoroughly warmed up and calibrated I Check carburetor pipes for proper connection

Warm up engine until water tem perature indicator points to the middle

2

engine

The is

procedure to warm up specifically recom

not

mended Either driving vehicle or oper ating engine at no load will be good 3

out

5Mn Mega ohms

assembly

Do not remove cables from cap

IF

Farad

Condenser insulation resistance

distributor cap as an

to 0 24

Micro

and

Idle

the use of

Make

that water tempera

sure

indicator points

to

the middle

Further keep engine running at about 2 000 rpm for about 5 minutes with

Condenser capacity

Disconnect

of secondary cables

with

adjustment

idle

CD meter

ture

denser tester Use an ohmmeter

CO

of gauge

outlet of condenser

and check for loose setscrew

Retighten

IGNITION WIRING

down

nipple

distributor

If plate does not move smoothly this condition could be due to sticky steel balls If necessary replace break

I

fully seated

tower Check distributor rotor for

damage cracks

plate assembly

causes

wires in ter

are

or

40 em 15 7 in

or

arcing between end of wire and ter minai

been N

d When measuring CO percentage in sert probe into tail pipe more than

be cleaned

which

seated

has

for automatic trans

position

P

to secondary reduce possibility of voltage loss All

system must

tip

cause

mission

cracks and flashover External

to

it

made shift the lever to the

for

points Inspect distributor cap

movement

er

is

operation

remove

Idle Limiter Cap After idle adjustment

formed while checking distributor

over

Inspect breaker plate for smooth

3

damage

To install idle limiter cap refer to

c

be inspected and cleaned

connection

cause

the idle

completely

If idle limiter cap obstructs proper

adjustment

corroded terminals indicate that wires

vacuum

could

so

screw

down

ew

malfunctions b

utor cap and coil so that terminals can

prob

following lem as required

CHECKING DISTRIBUTOR CAP ROTOR AND CONDENSER

wires should be removed from distrib

for the

items and correct the

sc

which in turn will tend to

and

DISTRIBUTOR

loose connection

Doing

cable

procedures

inspection

reference data

adjusting

Checking high tension

California models For

Do not attempt to

a

ADJUSTING CARBURETOR IDLE RPM AND MIXTURE RATIO

applying load

stabilize

engine

to

engine

in order to

condition

Engine

hood should be open 4 Run engine for about 10 minutes at

idling speed During this 10 proceeq as described i steps

minutes

5 to 9 below 5

Remove air hose between 3 way 5 way connector for Cali

connector

Cautions a

On automatic

fornia models transmission T 11

equip

shown in

and air check valve

Figure

ET 17

Plug

as

the dis

r

Engine connected hose to prevent

12

dust from

Connect

Tune up

air hose to air

check

valve

entering To air check

If

valve

10

Repeat procedures

increases

engine speed

the specified speed adjusting screw

to

readjust

it

with throttle

speed for

in step 9 can be carried out

not

following procedures Fig ET 17 Disconnect air hose from ojr check valve 6

Race engine

1 500 to 2 000 rpm two or three times under no load then

engine for speed run

minute at

one

idling

step

Adjust throttle adjusting until engine is at specified speed

screw

position

it to

for

If

Ignition timing

rpm

Non California

California

position

idling speed

engine

adjust

idle

adjusting screw so that CO percentage is at specified level

idling

peed

minutes proceed 5 to 9 below 5

D

and make

centage

three times under

is obtained

specified

10

described in steps

and

modeis

hose

air

air check

to

If engine speed increases the

specified speed adjusting screw to

readjust

it

with throttle

IDLE LIMITER CAP Do not

air

check valve

unless

1

as

After

If this

unit

is

follows

adjusting

speed adjusting Sure

that the

tained

in

throttle

check to be

screws

amount

exhaust

idle

or

of

gases

CO

con

meets

the

established standard 1 500 to 2 000 rpm

2

Install idle limiter cap in position sure that the adjusting screw

further

minute at

one

idling

turn

1 8

rotation

in

the

CORICH direction

throttle

Adjust

that

this idle limiter cap

necessary

proceed

engine for speed 7

remove

removed it is necessary to readjust it at the time of installation To adjust

making

adjusting

engine speeds

are

as

screw so

indicated

Carburetor stopper

below

815 rpm Automatic transmission D

in

position

670 rpm

at 650 rpm

that

Connect

two or three times under no load then

position

sure

12 valve

Manual transmission

ldle limiter cap

3lSo T

Repeat procedures as described in steps 6 7 and 9 above so that CO percentage is at specified level Check ing idle CO in step 9 can be carried out right after step 7 11 I 500 to 2 000 Race engine two or

position

15 to 25 rpm

Engine speed

10

rpm

as

this

5 way connector for Cali

Race engine

at

tI 2

During

Remove air hose between 3 way

750 rpm Automatic transmission in

to

Engine

shown in Figure ET 17 Plug the dis connected hose to prevent dust from

CO percentage Manual transmission tI 2

condition

D

in

Run engine for about 10 minutes

run

At about 10 minutes after at

without

engine

6

120 650 rpm

run

minutes

2 000

entering


is

at about

load to engine in order

fornia

Manual transmission

9

good

stabilize

neces

specifications

120 750 rpm

5

about

connector

D

up

that water temperature

applying

at

This operation need not be carried at 1 600 Ian 1 000 miles service

in

at no load will be

sure

rpm

60 to 70 rpm Automatic transmission

specifically recom Either driving vehicle or oper

Make

4

out

750 100

warm

screw

hood should be open

Check ignition timing

adjust

to

specified

not

ating engine

rpm

650 rpm

sary

The procedure is

engine

idle adjusting

Manual transmission

Wann up engine until water tern perature indicator points to the middle of gauge

the

Engine speed drops off

2

keep engine running

750 rpm Automatic transmission

8

below

indicator points to the middle Further

Manual transmission

D

may be used

Turn

clockwise until engine speed drops off

connection

3

Engine speed

in

the

Check carburetor pipes for proper

mended

7

available

right after

7

II

If CO meter is

engine

best idle mixture is 815 rpm manual transmission models and at

670 rpm for automatic transmission models in D position Adjustment

CO Idle adjustment without COmeter

I

described

as

in steps 6 7 and 9 above until

no

load

CO per

8


adjust it specifications

if

neces

to the value

required by This operation need not be carried out at 1 600 Ian 1 000 sary

miles service 9 is

At about 10 minutes after run

adjusting

at

idling speed

screw

engine adjust idle

until maximum rpm is

obtained

Fig ET 18 Setting idle limiter cap

CHECKING CARBURETOR RETURN SPRING Check cracks

throttle

squarene

necessary ET 12

ET031

replace

s

return or

with

spring for

defonnation a new one

if

Engine CHECKING CHOKE MECHANISM

that bimetal is out of order Refer

or

in

Carburetor

to

Choke

Tune up

Section EF

All

engines

cartridge

type

replaceable

a

use

fuel

filter

as

an

as

sembly

plate and linkage 1

Check

choke

valve

and

mech

anism for free

operation and clean or if replace necessary A binding can result from on

2

petroleum

choke shaft or from

Check

bimetal

Index mark

on

bimetal

gum formation

damage cover cover

CHECKING FUEL Hoses

pipings

connections

setting is usually

etc Check

set at center of scale

nections Note

Always align the index mark

bimetal mark

cover

on

on

with the center index

fuel

lines

cracks

and

for loose

con

deterioration

Retighten loose connections and re place any damaged or deformed parts

choke housing

Every day before starting engine depress the accelerator Pdal to see if choke valve is closed automatically 3

REPLACING FUEL FILTER

If it fails to be closed the chances are

@

LINES

that link movement is unsmooth

Check for water

a

ET011

contaminated filter and

Fig ET 19 Fuel filler

deposit

EMISSION CONTROL SYSTEM CONTENTS ADJUSTMENT OF SET PRESSURE OF

CHECKING CRANKCASE EMISSION CONTROL SYSTEM REPLACING

BOOST

ET 13

P C V

CONTROLLED DECELERATION

DEVICE

VALVE AND

B CD

D

ET 18

FILTER

ET 13

CHECKING

B C D D

CHECKING VENTILATION HOSE

ET 14

CHECKING

AMPLIFIER

CHECKING EXHAUST MANIFOLD HEAT CONTROL

CHECKING SPARK

TIMING

TION

Automatic transmission models only INSPECTION

CONTROL

CHECKING

DELAY VALVE

CHECKING

ET 15

CONTROL

OPERATING

CHECKING B C DD

CHECKING

BOOST

CIRCUIT

ET 20

RECIRCULA ET 20

CONTROL SYSTEM

EVAPORATIVE

EMISSION ET 22

SYSTEM

ET 23 ET 23

INSPECTION FLOOR TEMPERATURE

ET 23

WARNING SYSTEM

CONTROLLED DECELERATION DEVICE ET 17

B CD D I ADJUSTMENT

CLEANER

CHECKING CATALYTIC CONVERTER ET 15

CLEANER

PRESSURE OF

ET 20

PUMP AIR

EXHAUST GAS

E G R

ET 14

AUTOMATIC TEMPERATURE AIR

Manual

ELEMENT ET 14

CHECKING

AIR

REPLACING

CONTROL

SYSTEM SPARK

ET 20

VALVE

transmission models ET 14

VALVE

SOLENOID

ET 23

INSPECTION

WITH

FUNCTION TEST CONNECTOR

ET 17

CHECKING CRANKCASE EMISSION CONTROL SYSTEM with the following method REPLACING P C V

VALVE

AND FILTER Check P C V

valve in accordance

noise

will

be

through

the valve is

finger is placed

properly working ET 13

a

hissing

should

heard

the valve and

With engine running idle remove ventilator ose from P C V valve If at

be felt

a

as

air

strong

immediately over

passes vacuum

when

valve inlet

a

Engine

Tune up 2

With

engine

check E F E

stopped

visually

system for the following

items 1

CoOl

2

Oil level gauge 8affle pia te

3

Flame arrester

4

Filter

5

P C V valve

6

Steel net

7

Baffle plate

Thermostat spring for dismount

I ing 2

Stopper pin for bend and count weight stop position for dislocation

er

3

heat

Check

control

valve

for

malfunction due to break of key that locates counterweight to valve shaft 4 Check axial clearance between heat control valve and exhaust mani

fold mm

o

1fiI Fresh air

Fig ET 20 Crankcaae emi

3

VENTILATION

full

HOSE 1

hoses

Check

and

hose

connec

tions for leaks

them

out with

If any

all

compressed

hose

and blow

hoses

cannot

or

flaking

Rotate heat control valve shaft

with a fmger and check for binding between shaft and bushing in closing and opening operation of heat control

control8 valve

If any binding is felt in rotating operation move valve shaft in the

position

counterweight moves further clockwise exceeding the position described in 1 1 above and stops again coming into contact with

Disconnect

2

6

rotation direction several times If this

When heat control valve is in the open

5 1

Check welded portion of heat valve and valve shaft for any

indication of crack

tem

ion

to

control

EC716

Blow by gas

CHECKING

5

Correct clearance is 0 7 0 028 to 0 059 in

operation condition

does

not

binding

correct

it is due to seizure between

shaft and bushing and exhaust mani fold should be replaced as an assem

bly

stopper pin

air

free of

be

obstructions replace Ensure that flame arrester is surely inserted

in

the

hose

cleaner and rocker

between

air

ct t

cover

C

CHECKING SPARK CHECKING EXHAUST

EC245

MANIFOLD HEAT CONTROL VALVE Fig Run engine

and

ET 21

1

Counterwe ht

2 3

Stopper pin Heat control valve

Cold operation of

weigh t

visually check

counterclockwise until

into contact with stopper to

Counterweight and

clockwise

ambient

This

moves

engine warms up temperature goes higher

discharge causes

pressure

of exhaust

counterweight

ward clockwise

gases

to move down

VALVE

only

valve

delays vacuum spark during rapid acceleration it also cuts off the vacuwn spark advance imme iately upon deceleration The valve is designed for one way opera advance

as

When engine speed is increased

on non

transmission

models

models

EC246

around exhaust manifold 2

automatic


pin installed

gradually

system is installed

California

SPARK DELAY

it comes

exhaust manifold

down

This

counte

counterweight to see if it operates properly For some time after starting I engine in cold weather counterweight turns

TIMING CONTROL SYSTEM

1 2 3

Counterweight Stopper pin Heat control

valve

Fig ET 22 Hot operation of counter weight ET 14

tion and consists of a

la

valve

restrictor

and

one

sintered

way umbrel

steel

fluidic

Tune up

Engine

CHECKING

Distributor side Brown

AUTOMATIC TEMPERATURE CONTROL AIR CLEANER 1 Air cleener element Viscous paper type air cleaner ele does not require any cleaning

ment

opera tion until it is replaced periodi

cally

Brushing

will cause lOne way umbrella valve 2 Sintered metal disc

should EC284

Fig ET 23 Spark delay valve

installing this valve ensure properly oriented This valve be replaced periodically Refer

When that

it

should to

Maintenance Schedule

Remove

2

Blow air

valve

spark delay through port on carbure then through the other port tor side on distributor side Spark delay valve is in good condition if when finger is side placed over port on distrib

3

If

a

considerable air flow resist

is felt at port

on

distributor side

in step 2 above and if the condition of

distribut0 Yl

EC278

From

spark delay valve carburetor

r

l

and

mixture

conducted

be

For

reo

placement interval of air cleaner ele ment refer to Maintenance Schedule

Hot elr control system

2 I

ance

To

carburetor

never

INSPECTION

ajr flow resistance is greater than that on the other side See Figure ET 25

I

and result in enrich

clogging

of

ment

blasting operation

or

is

questionable dip

In find

warm

ou t

system

it is difficult to

wealher

malfunction of hot air control In cold weather however

malfunction of air control valve d

um

to

hose between intake manifold and

bility

dura

motor and insufficient

vacuum

of air con trol valve will cause control opera and result in engine

automatic

insufficient

tion for intake air

disorder including hesitation of engine opera

port on carburetor side into a cup fIlled with water Blow air through the

I

other port Small air bubbles should

2

Increase in fuel consumption

appear

3

Lack of power

Stall

or

tion

Fig ET 24 Operation ofspark delay

These

value

e

disconnection or deterioration of vacu

phenomena

reveal

malfunc

tionof hot air control system

phenomena air control

should system

check hot

occur as

If these

described in the

following before carrying

out

inspec

tion of carburetor

2 1 Vacuum hoses

I

Intake

I

tor

sensor

Carburetor side

um

connec

to temperature

3 way connector to idle com

pensator

Distributor side

manifold to 3 way

3 way connector

temperature

sensor

to vacu

motor

EC279

Fig ET 26 Checking spark delay ualue 1

lr EC346

rJmlL

Fig ET 25 Checking spark delay value

Note

or

Check that

curely 2

Be careful

to

avoid entry of oil

dirt into valve ET 15

vacuum

connected

hoses

in correct

are

Check each hose for cracks

distortion hose

clip

se

position

for condition

or

Engine Note

Vacuum

hose

Tune up

sensor

mark

on

side of the mark is for

grad

ually opens to under hood air inlet side as engine warms up When en

the

top of for intake manifold L R

side of Nissan

Check that air control valve

3

R R

position

vironmental temperature around perature sensor is low spend

vacuum

rootor

time for

engine warming

tern more

operation

up

facilitate smooth opera tion of air con trol valve to

If the above test reveals any prob operation of air control

lem in the EF217

Fig ET 28 lmpecting value position

temperature sensing

2 2 Vacuum motor

I

engine stopped

With

Correct pC6ition of air control valve disconnect

fresh air duct Place

cleaner inlet

is the reverse of paragraph I above

control valve is in

mirror at

a

pipe

valve carry out the following test Remove air cleaner cover

as

the end

of air

shown and check

to see if air control valve is in correct

position

Air

position

correct

if

Set

4

element

of ther

thermometer to a

mistor or

position

where tempera ture around sensor can be measured In this case fix wiring of

under hood air inlet is closed and hot

thermistor

air inlet is open

tom surface of air cleaner with adhe

With hot air inlet is open posi

3

tion

descnbed

as

above

in

and cut of air from this condition valve

paragraph 2 fingers

hose with

pinch vacuum

vacuum

hose

In

thermometer

or

on

the bot

tape in such a manner that the set position of temperature sensing ele ment will not be affected by airflow sive

Then install air cleaner cover

check that air control the

maintains

de

condition

2

scribed in step for more than 30 seconds and that hot air inlet is open If

actuates the air

diaphragm spring

control

valve

spring force

by its

to

open under hood air inlet within 30

seconds

replace

vacuum

assembly since this EF213

Fig ET 27 Impecting lJalv

position

from

motor as an

may be resulted

air leak at vacuum

motor

dia

phragm EF221

Fig ET 29 Checking

2 3 Temperature sensor Check temperature

temperotur e ensor

sensor

for func

tion to

Air control valve is in correct posi tion if its under hood air inlet is open

and hot air inlet is closed Check air control valve linkage for condition 2

Disconnect

vacuum

hose

to

vacuum

hose

vacuum

and

the inlet motor

to

apply

Vacuum

plied by breathing

motor

connect

inlet

another

vacuum to can

be ap

in the hose end as

shown Place

a

mirror

at

the

end of air

cleaner inlet pipe and check to see if air control valve is in correct position

by proceeding as follows Be sure keep engine cold before starting

5

Carry

steps

1

control valve

With engine off check air control

valve for condition

In this

hood air inlet is open Use

inspection

2 2 1

as

a

mirror for

above

Start engine and

2

under

case

keep idling

Immediately after engine starting check

air control

position

as

for correct

described above

case

correct

valve

is

the

valve

position of reverse

inlet is open

ET 16

this

air control

of 2 2 1

hood air inlet is closed

In

under

and hot air

I

out

test

2

hood air

and

test

as

described in When air

3 above

begins

inlet side

to open to under severa

minutes

after engine starting read the indica tion of thermistor or thermometer If

reading falls within the working tern perature range of temperature sensor the

sensor

ceeds

the

is normaL range

with

new one

Note

Before

If

replace

reading the

ex

sensor

replacing temperature check idle compensator as 8 EF described in Section EF page sensor

Engine

If voltmeter reading is

OPERATI NG PRESSURE

Tune up zero

for disconnected connector

OF

solenoid valve

BOOST CONTROLLED DECELERATION DEVICE B C D D

2

With 41

or

inhibitor

2

D

or

ADJUSTMENT CHECKING a C D D CIRCUIT WITH FUNCTION TEST CONNECTOR

erly If ohmmeter reading is 32 ohms or above check for poor connection

inhibitor switch switch R

Refer to

of connector

OFF

@

and

Figure ET 31 If ohmmeter reading is 25 ohms or below circuit is functioning prop

faulty

B C D D

noid valve or inhibitor

position

check for resistance between

@

check

faulty

3

sole

relay

If by above checks faulty part

unit is located and tested

or

should be removed

it

again If necessary replace

models

Manual transmission

Check for continuity between @ and@ at a speed of zero km Refer I

Figure

to

ET 30

BC D D

circuit

functioning

is

l

properly if continuity exists and volt meter reading is 0 volt d c in step 2

E

below

for

1

switch

amplifier

detecting

speed

B C D D solenoid valve

or

Check

for

Ignition key

2

Fuse

3

Amplifier Speed detecting Above 10 mph Below 10 mph

4

If continuity does not exist check disconnected connector and or

faulty 2

r

switch OFF ON

5

Function test connector

6

B C D D

solenoid valve

of voltage

presence

@ and @ at a speed of more than 16 km h 10 MPH Refer to across

Figure

EF711

ET 31

Fig ET 30 B C D D circuit with function tedconnectoT Manual transmission modela

Conduct

following

this test by

one

of the

two methods

iRaising

up

rear

axle housing with

stand 2 Chassis dynamometer test If voltmeter reading is 0 volt at

speed MPH

of more than circuit is

16 km h

functioning

@

a

10

prop

erly If voltmeter

reading

is not 0 volt

check for disconnected connector burned

fuse

BC D D

solenoid valve

faulty

amplifier or

speed

detecting switch 3

If by above checks faulty part

unit is located

1

Ignition key

2

Inhibitor switch

or

3

it should be removed

4

and tested again If necessary replace


5

N

P

I

2

positions ON D R positions

OFF D C D D solenoid valve Function test connector Inhibitor relay

EF712

models I or

With inhibitor switch ON P position

voltage

across

UN

Fig ET 31

and

@

Refer to

Figure ET 30 If voltmeter c d

reading

BC D D

is

circuit

12

volts

is

func

tfst

connfctor

Automatic transmiMion modtla

check for presence of

@

Checking B C D D circuit with function

tioning properly ET 17

r

Tune up

Engine ADJUSTMENT

Refer to the idling setting Idling Adjustment in page ET II

OF SET

PRESSURE OF BOOST CONTROLLED DECELERATION DEVICE

it

Manual transmission 750 rpm

is unnecessary to ad


just the B C D D however if it should become necessary to adjust it the procedure is as follows

in

D

position

650 rpm 1

4

Run the engine under no load Increase engine speed to 3 000 to

Prepare the foUowlnB tools I

Tachometer

the

to measure

gine speed while idling and

en

a screw

driver 2

Note

A

connecting pipe

qui k response type such

gauge

Bourdon

as

recommended

a

boost

type is type

s

mercury

manometer should not be used To

properly

pressure I

3 500 rpm valve

5

A vacuum gauge

proceed

Remove

set as

models

Idling engine speed

B CD D

Generally

california Non

item

the

B C D D

then

quickly close throttle

At the time

the manifold vacuum

ET037

to

600

above

and

abruptly

23 62 inHg

mmHg then gradually decreases

or

r

the level

to

idling

6

Check that the BC D D

sure

is within the

specified

set

pres

pressure

set

follows

the harness

Specified

of solenoid

and

valve

screw

e

Cover

California models

pressure increases

set at

Adjusting

2

0

pressure

760 mmHg

m

sea

30 inHg

level

atmos

1

Adjusting nut Lock spring

2

EC692

pheric pressure TO

D D

solenrod

Manual transmission

VT FJ

510 to

550 mmHg

20 1 to

BC D D

1

Fig ET 34 Adjusting Bet pressure

solenni valve harness

8

7 inHg 21

Automatic transmission 490 to

J

turn the

20 9 inHg

correct 10

Note

When

y

pressure in

EF262

For

Connect

rubber

hose

Figure

IT 36 from the

pressure and altitutde

sion model vehicle is located at an altitude of 1 000 m 3 280 ft the

between

gauge and intake manifold as

specified

shown

set

for B C D D

preSsure

445 mmHg

17 5 inHg

Race

If it is higher than the set level turn the adjusting screw counter clockwise

nut

or

adjustment

clockwise

until

is made

screw

nut

vacuum

gauge

Note

When

type

California

higher than the

nut 3

Warm up the engine until it is heated to operating temperature Then

adjust

the engine at normal

in or out

place Always erly

BC D D turn

with lock set lock

to prevent

changes

sure

In

for

set

this

case

to

The engine

to

idling speed pressure is

pressure of the

the

engine

road test

must

be

2 chassis

or

or

adjusting

the accelerator

spring

vehicle

spring

in

prop in set pres

to 64 to 80 krn h

in in

matic transmission

top gear manual position auto

D

and then

pedal

decelerate

and

releasing letting the

After doing this

check whether the B C D D set pres sure is at the predetermined value or not

ET 18

necessary

B C D D

40 to 50 MPH

type

models

does not fall

negative idling

erating the vehicle

adjusting

is

drop

not

transmission

Fig ET 33 Connecting

speed

it

dynamometer or 3 by raising up rear suspension member on a stand accel

California models

Adjusting

nut until

and check for

pressure of the B C D D

labored by I


Adjusting

or

reduce the negative idling pressure of the manifold to lower than the set

speed will

7

engine

idling speed

to

when the

correct

the

screw

is made

When the engine

if a manual transmis

example

adjusting adjustment

adjustment If engine speed cannot be decreased to idling when checking B C D D set pressure proceed as follows

of the given location

solenoid valve

vacuum

set pressure find the specified set

atmospheric

g ET 32 Removing harneS5 of F

2

checking the

of B CD D

ri

and check for

If it is lower than the set level

9

530 mmHg

3 to 19

Race the engine

adjustment

Engine

Tune up

Vacuum gauge

Vacuum gauge

Vacuum gauge

Intake m

dJi

1 2

I Road te t

Raise

3

Otassis dynamometer

up

rear

housing by

stand ET133

Fig ET 35 Testing

mmHg

axle

set pressure

inHg

inHg

of the B C D D

mmHg 30

24 750

600 29 23

28 22

700

550 27 21

26 20 650

500 25

a

19 a

Co

11

1

Co

v

24

g

8

Co

18 600

450

0

E

0

23 17

22 16

550

400 2 15

0

20

14 500

350

19

13

300

1 o

1

000

2 000

3 000

4

000

5 000

6

000

ft Altitude

o

0

5

10

5 1

2

0

km EF55B

Fig ET 36 Changes in set pressure uersus changes in atmospheric pre6Sure and altitude ET 19

r

Engine 3

CHECKING B C D D SOLENOID VALVE

If

Turn

on

Do not start

engine key

engine 2

Ensure

when

that solenoid valve clicks

intermittently

click is heard solenoid valve

a

is normal 4

I

Tune up

electrified

If a click is

for

continuity

not

with

heard at all a

check

circuit tester If

discontinuity is detected replace sole naid valve

as

shown in Figure ET 37 CHECKING AMPLIFIER Manual transmission

EC323

Fig ET 39 Repl4cing air cleaner

models

element The

of the as

1

amplifier is installed at the rear speedometer To check proceed

follows Set circuit tester in

range

IA min full scale

probes of

tester

c d

ampere

connect test

shown in Figure

as

ET 38 Do not confuse

Fig ET 37 Checking solenoid

l uolV

line with

positive

negative line

CHECKING EXHAUST GAS

RECIRCULATION

E G R

CONTROL

SYSTEM Checkln

I

E G R control

system In Ita mounted condition

l

I

M ake

E G R

M

wipe

1

o L

I

of

2

J

f

T Ignition key Amplifier Speed detecting

2

EF264

3 4

B

Make

not

inspect harnesses and con replace warning lamp Then ignition switch to ON position

nectors or switch

turn

C D D solenoid valve

and check the I

has make

Ensure that tester pointer deflects when ignition key is turned on 4 If tester panter does not deflect when solenoid valve and speed detect ing switch circuits are functioning

properly amplifier

is

faulty

ELEMENT

check harnesses

cleaner from

hoodledge

Air cleaner

element and air cleaner lower body built into

a

unit construction

air cleaner element and lower an

assembly

are

If warning tector

lamp

drive or

does

lamp

not

lamp light

and de connector

counter

detector

replace warning

drive

counter

if

necessary

Replace body

as

Note

Operation

lamp ET 20

warning

that E G R warning

lights

then detach air

that E G R

has attained 50 000 counts

sure

REPLACING AIR PUMP AIR CLEANER Remove air hose

50 000

reached

not sure

If odometer of detector drive

make

3

items

does not light

counter

posi

following

If odometer of detector drive

2

ON

that E G R warn

sure

light

lamp

to

proper

If E G R warning lamp does

tor runs

counts

Turn ignition key

check

engine running warning system for

counter

tion

fe

ing lamp light when ignition switch is turned to START position starter mo

Fig ET 38 Checking amplifiu

2

inspection broken

With

E G R

function

1

or

place

A jt

system

cracked

are

check of

If necessary

oil to facilitate

away

If hoses

II

p

thorough visual

a

control

is

as

of E G R

follows

warning

Tune up

Engine Ignition Switch Position

ON

START

Detector Drive Counter

a

After

completing

EG R

control system

inspection be

sure

to

620 models

um

engine

inspect vacu

valve for normal operation When engine coolant tempera

ture

EC254

is low

Make

Fig ET 41

Checking thermal

that E G R control valve

sure

operate when engine speed is increased from idling to 3 000 to

vacuum

valw

does not

and Canada With

running

E G R control valve and thermal

except those bound for California

3

With

4

I

applies

ON

OFF

to

counter to zero

b This item

50 000 counts

of

odometer of detector drive

reset

Above

50 000 counts

ON

Warning Lamp

E G R

Below

stopped

engine

inspect

E G R control valve for any indication of binding or sticking by movirig dia phragm of control valve upwards with

3 500 rpm Place fingers

on

the

diaphragm of

E G R control valve to check for valve

operation

If any difficulty is encountered in judging the condition of any compo check nent during above inspection the questionable component independ ently as follows

fmgers

E GR

control valve

Dismount

EG R

control

valve

from engine I

Apply

control

to E G R

vacuum

valve referring to the following figure If the valve

moves to

full position it is

normal EG R

control

valve will remain

open for more than 30 seconds after vacuum

has cut off

EC253

Fig ET 40 Checking E G R control valve

0 r11

hC

J 2

When

ture is I

engine coolant tempera

control valve

that E G R control valve

Increase engine speed from idling to 3 000 to 3 500 rpm

high

Make

sure

operates when engine speed is in creased from idling to 3 000 to 3 500

rpm

Place

diaphragm of

to check for valve

2 If E G R

the

control valve

operation

Disconnect

one

as

follows

end E G R control

ofvacuum hose connect

ing thermal

vacuum

valve

to

sure

that

valve is open vacuum

is

thermal

at

the

end

2

Visually

valve for

check

damage

E G R

wrinkle

or

control deforma

tion

If vacuum is weak

or

all

vacuum

thermal

is present trol valve

vacuum con

ET 42 Checking E G R control VGlve

and that carburetor

present

hose

replace

Fig

vacuum

E G R control valve side ofvacu urn

control valve does not

operate check

valve side

fingers

E G R

on

Make

ET152

EG R

not

present

replace

at

valve If E G R

3

Clean

E G R

compressed matter

port ET 21

the

seating

control valve with

from

air

and

around

surface a

remove

the

of

brush and

foreign

valve

and

Engine

Tune up little

CHECKING EVAPORATIVE EMISSION CONTROL SYSTEM

until

mmH20 5

the

Shut

6

After 2 5

Cleanil E G R control l

Fig ET 43

Jlue lJ

8

Checking fuel tank vapor liquid separator and vapor vent line I

all

Check

the

measure

When

does

filler cap

height

the

zero

in a short time

9

If the

not

close

should drop to

height does

not

drop

to

filler cap is zero in a short time when

and fuel tank

hoses

minutes

height of the liquid in the manometer 7 Variation of height should remain with 25 0 98 inH20 l20 mm

completely EC350

and

completely

cock

leave it unattended

Vapor Rnes and fuel vepor control valve r

368

becomes

pressure

14 5 inH20

roler cap

removed

it is

the

cause

of

a

stuffy

hose

line vapor vent canister to vapor connecting carbon

2

Disconnect

the

liquid separator Thermal

VBCuum

3

valve

Connect

a

manometer and

Dismount

thermal

vacuum

valve

from engine

lent

a

cock

charge cock

way 3

or

an

a

equiva

the end of

to

the vent line

Supply fresh vent line through

air into the vapor

connectoT

36

4

Note

Before dismounting gine coolant from engine

Apply

connector

way 3

vacuum

drain

e

the cock little

In case the vent line is

Note

the breathing

in fuel

stuffy

tank is

not

in

causing thoroughly made thl suffICient delivery of fuel to engine or

vapor lock It must therefore be

repaired

by

or

replaced

to thermal vacuum way 3

valve and check to be sure that ther

mmH20 14 5 inH20

valve opens or closes in response to engine coolant tempera mal

vacuum

lt U iYCl

i i1

lurt

valve should open of 57 to 630C 134 temperature 1450F completing the vacuum

Thermal at

to

a

vacuum

c

Do

not

aUow water to

inside the thermal

vacuum

s

@

passage Note

W

I

get

Carbon canister

valve

r EC786

Fig ET 45 Checking evaporative emission control By

Checking

carbon canister purge

control valve

I

Check for fuel vapor leakage in the distributor VC line at diaphragm of carhon canister purge control valve To check for leakage proceed

I

L

as I

follows 1

line

Disconnect

242 EC

Fig ET 44

rubber hose

at

valve

the

Tconnector

Inhale

rubber hose

air into the

running

carbon canister and

lChecki thermallXlCuuml

in

between T connector and carbon

canister 2

tem

opening

to VC

ensure

of ET349

hole in

that there

Fig

ET 46

Checking

carbon cani ter

purge control valve

is no leak ET 22

Tune up

Engine 3

If

leak remove top contiol valve and purge check for dislocated or cmcked dia cover

there

is

a

from

phragm phmgm retainer

If kit

ance

is felt

replace

if

or

no

as an

cap

resist

assem

8

Adjust idle adjusting screw until specified CO percentage is obtained Refer to page ET 12

bled unit

9

necessary replace dia which is made up of a

diaphragm

If valve is clogged

3

Repeat the adjustment process as described in steps 5 to 8 above until specified CO percentage is obtained

r

and spring

Adjustment

Note

in

step 9 should be

u

made ten minutes after engine has warmed up

I

10

@ ET369

49 ET

Fig

Fuel filler cap

Cover

2

Diaphragm

3

Retainer

4

Diaphragm spring

CHECKING CATALYTIC

control valve

Element

contaminated element

be

can

removed at the on

cap

and

air

connect

Visually

check

condition

of all

component

parts

including

hoses

tubes

body

and wires

Refer to

replace

if necessary

Inspection of

A I S

on

page EC 17

speed pleted

After step 12 has been com wait for one minute before

making CO percentage measurement 14 If CO percentage measured in 13 is less than 3 0 the catalylic step converter is normal

If CO percentage measured in recheck IS A 3 step 13 is over 0 air valve Then and replace check

Whether catalytic converter is or

engine for about four

15

Catalytic converter

mal

screw

Warm up

minutes at 2 000 rpm under n load 13 Measure CO percentage at idling

INSPECTION

vehicle

speed increases readjust it specified speed with throttle ad

12

Preliminary inspection

bottom of canister installed

load

sure

Remove

justing

CONVERTER

Carbon unlster filter a

2 000 no

If idling to

ET 47 Carbon caniater purge

Check for

to

three times under

hose to air check valve

ET350

Fig

or

that specified CO per centage is obtained I1

1

engine 1 500

Race

rpm two and make

not

nOf

be

checked by ob in CO percentage

can

serving variation The checking procedure

Apply parking

is as follows

brake

Shift

gears

into Neutral

for manual transmission

and

or

Neutral

steps 12 and 13 If CO percentage is still over

perform inspection 16 03

in step 15

catalytic

converter is

malfunctioning Replace catalytic

con

verter

for automatic

Park

transmission 1

Visually check catalytic

for damage Fig ET 48 Replacing carbon canister filter

2

or

relief

valve operation Remove fuel filler cap and functions properly I

see

it

connector and air check valve

companied valve is in

by

good

slight

valve

resistance ac

indicates

hose

to

Plug

that

mechanical condition

the

prevent dust

TEMPERATURE WARNING SYSTEM

from entering Refer to page ET 12 3 Check carburetor pipes for proper

INSPECTION

connection

Floor warning temperature

4

system

5

Warm up engine sufficiently Race engine 1 500 to 2 000 rpm

two or three times under no load

Wipe clean valve housing and have

it in your mouth 2 Inhale air A

CHECKING FLOOR


disconnected

Fuel tank vacuum

converter

cracks

engine for speed run

6

Adjust

one

minute at

throttle

until engine attains to Refer to page ET 12 7 sary

with valve clicks

to page ET 10

adjust

it to

idling

adjusting screw specified speed


Note also that by further inhaling air the resistance should be disappeared

into Neutral

brake Shift gears for manual transmission

and Neutral

or

Apply parldng

then

1

Ensure

warning If

specifications

neces

Refer

that

floor

lamp lights

If not

check

tern perature

when

switch is turned to the

bul bs ET 23

for automatic

Park

transmission

lamp

S

ignition position

for burned

Tune up

Engine Replace bulb if bulb back

wireis Repair or

replace if necessary 2

Be

sure

that floor temperature is

below 800C

cool

carrying

out the

1760F

before

following procedure

1

Remove

rear seat

2

Ignition

switch is turned

to

the

results do not floor

3

trace

ignition switch

to

IGU position Ensure that

is burned ou t

If bulb is not burned

tem perature

the above

reo

warning lamp goes out 4 Heat surrounding areas of floor temperature sensing switch with a proper heater

to

ensure

that

floor

glows when

temperature warning lamp floor is heated to lh specifications

as

shown in the table below

When floor temperature

lamp 118hts

warnln8 Check

Temperature sensing switch

satisfy

place the floor temperature relay

floor temperature

warning

lamp

Temperature warning lamp

Floor temperature

I

Open

short circuit in wiring

or

harness

Contact close

2

Off

Below 1050C

22IOF

the

Check fuel system with regard to following items Refer to Inspec

tion of Fuel

Contact open

On

Above 1050C

2210F

Floa t level

2

Choke

3

Normal fuel supply system ry and

Note

heating floor tempera sensing switch directly

Avoid

ture

If lamp

does not

cinq sen

the wiring back to relay

following step wire s

circuit tester

Referring

normal

or

Repair

check the or

replace

Accelerator pump Power valve

6

BC DD

7

Fuel strainer

8

Air cleaner

switch

3

by a proper heater

rela

To

check floor temperature relay remove it and proceed as follows Check for continuity

and@ Continuity

disconnect floor temper position anf sensing connector The lamp

ature

If not check floor

2

@

continuity between Continuity should not exist

Apply to

a

ensure

12 volt doC that

2

Distributor

3

Ignition coil High tension code Spark plug

4

4

Check idle CO

to

Inspection

CO

Refer

Adjust

D Note

across@and

continuity

adjustment

of Idle

roeoC

should exist

Check for IG

D

Ignition System

IgnItion AMI

5

should exist for continuity between

of

I

between@

@ Continuity

Check

and@ Turn ignition switch to the

Check ignition system with regard Refer to following items

the

Inspection

1

Prima

secondary

5

to

and

on

floor

following

Floor temperature

The floor temperature sensing switch may be heated through the

should remain

the

temperature relay if relay is trace wire s back to ignition Repair faulty wiring

Note

3

to

trace

if necessary

floor

with

reolace tem

Vitch S

perature sensing switch If continuity does not exist 3

a

glow check floor

temperature sensing switch connector for continuity with a circuit tester If continuity should exist after heated surrounding areas offloor tern wnTP rv

4

temperature relay for continuity

System

I

Even if there is

with

exists

come

between D and@and that continuity does not between D and @ If test

on a

lower

nothing wrong warning lamp may on if vehicle is being driven steep slope continuously in gears at high engine speeds

engine

4 03

UJ GJO

To floor temperature

warning lamp 2

From S

position

GOt position 4 From ignition switch

r I 141

3

From

5

To floor

temperature

sensing switch

Fig ET 24

50 ET

EC343

Checking floor temperature relay

Engine

Tune up

SERVICE DATA AND SPECIFICATIONS Ignition timing and idling Manual transmission

degree

120 B T D

rpm

100 B T D

jC 750 j750 C

l20B T D

j650 C

Non Calif models California models

Automatic transmission in

D

degree

position

rpm

Valve clearance

Cold

Hot

Intake

mm

in

0 20 0 008

Exhaust

mm

in

0 25 0 010

Intake

mm

in

0 25 0 010

Exhaust

mm

in

mm

in

0 012

30 0

Belt tension Fan Air pump

mm

Air coo compressor

mm

Pressure

kg lb

8 to 12

315 0

to

in

8to 12

315 0

to 0472

in

8 to 12

315 0

to

22 is

10

472 0

0 472

applied

pressure at 350 rpm

Compression

Standard

kg

cm2

psi

12 0 171

Minimum

kg

em2

psi

9 0 128

kg

em2

psi

09

kg

cm2

Psi

Radiator cap relief pressure

13

Cooling system Leakage testing pressure Battery specific gravity

at 200C

1 6 23 1 26

680F

Distribu tor Point gap

mm

in

0 45 to 0 55

Air gap

mm

in

0 2 to

Dwell angle

degree

490

Condenser capacity

IF

0 20 to 0 24

Condenser insulation resistance

Mil

5

0 018 to 0 022

4 0 008 to 0 016 0

to 550

Spark plug Gap

mm

0 8 to 0 9 0 031 to 0 035

in

Breaker points type 10 to 1 0 039 to 0 043

Transistor ignition Checking

CO

percent

at

idling speed

type

No air

Manual transmission model

rpm

21 1 750

Automatic transmission model

rpm

2 1 1 650

Adjustment of operating pressure of B C D D BC D D set pressure Manual transmission Automatic transmission

mmHg in Hg mmHg in Hg

ET 25

510 to

550

20 1 to

21 7

490 to

530

3 to 19

20 9

r Engine

Tune up

A TC air cleaner

Operating

temperature

OC

OF

30 to 54 86 to 129

Tightening torque Cylinder

head bolts

1st turn

kg

m

ft b

4 0 29

2nd turn

kg

lll ft lb

6 0 43

3rd turn

kg

m

ft lb

Manifold nuts

kg

m

ft lb

12 to 1 6 8 7 to 116

Carburetor nuts

kg

m

ft lb

0 5 to 10 3 6 to 7 2

Spark plugs

kg m

ft lb

1 5 to 2 0

ET 26

5 to 8 5 6

47 to 61

II to 14

Engine

Tune up

TROUBLE DIAGNOSES AND CORRECTIONS Condition

Probable

CANNOT CRANK

Improper grade

ENGINE OR SLOW CRANKING

oil

Replace with proper grade oiL

Discharged battery

Charge battery

Faulty battery

Replace

Loose fan belt

Adjust

Malfunction in charge system

Inspect

Wiring connection loose

Trouble Switch

When

starting circuit

in

Correct

Faulty ignition switch

Repair

or

replace

Faulty starler

Repair

or

replace

motor

shooting procedure on starting

on

Corrective action

cause

the starting motor with

light

circuit

ON

light

goes off or dims considerably a

Check battery

b Check connection and cable

When

light

c

Check starter motor

a

Check wiring connection between battery and starter

stays bright

motor

b Check ignition switch c

Check starter motor

ENGINE WILL CRANK NORMALLY BUT WILL NOT START

In this case the

following

trouble

Ignition system

causes

may exist

but in many

cases

ignition system

or

fuel system is in trouble

in trouble

Fuel system in troubk Valve mechanism does Low

not

work

properly

compussion

Trouble shooting procedure Check

spark plug firstly by following procedure high tension cable from one spark plug

Disconnect about 10

mm

0 39

in

and hold it

from the engine metal part and crank

the engine Good

spark

occurs

Check

spark plug ignition timing

b Check c

Check fuel system

d Check No

spark

cylinder compression

occurs

Very high

current

Check the current f10

in

Inspect primary circuit

for short

Check breaker

poiIit

sistor ignition system

ET 27

primary circuit

operation except

tran

Engine

Condition

Probable

Low

or no

Tune up

Corrective action

cause

current

Check for loose terminal

or

disconnection in

primary circuit Check for burned points

Ign

tion system out of

Burned distributor point

Repair

Improper point

Adjust

replace

or

order

gap

Faulty condenser

Replace

Leak at

Clean

or

Faulty spark plug

aean

adjust plug gap

Improper ignition timing

Adjust

Faulty ignition coil

Replace

Disconnection of high tension cable

Replace

rotor

Loose

cap and rotor

connection

disconnection

or

in

Repair

replace

or

or

replace

replace

primary circuit Fuel system out of order

Lack offuel

Supply

Dirty fuel strainer

Replace

Dirty

Fuel pump will

not

Clean

properly

Repair

or

replace

Check and

Improper adjustment

Correct

of float level

adjust

Improper idling

Adjust

Dirty

clogged carburetor

Disassemble and clean

breather pip

Repair and clean

or

Malfunctioning comp ion

work

Carburetor choke will not work properly

Clogged

Low

fuel pipe

clogged

or

an ti

of fuel tank

dieseling solenoid valve

sparle plug tightening

Incorrect

or

faulty

Check for loose terminal or wire harness to normal

Tighten

gasket Improper grade engine

oil

or

low viscosity

Incorrect valve clearance

Compression Sticky Weak

Sticking

or

Pour

valve springs

leak at

cylinder

Replace

head gasket

damaged piston ring

Worn piston ring

Trouble

Remove

cyljnder

Correct or

damaged

Compression

with proper

or

grade

or

replace gasket

oil

Adjust

leak from valve seat

valve stem or

Replace

torque

head and

replace

valve

lap

valves

valve and valve

guide

springs

Replace gasket Replace piston rings

cylinder

Overhaul

engine

ooting procedure

the engine

oil

from

plug

hole

and then

measure

cylinder compression

Compression

increases

Compression

does not

Malfunctiong cylinder

change

Compression leaks or head gasket

or

piston ring

from valve cylinder head

Except transistor ignition ET 28

system

Engine

Probable

Condition

Tune up

Corrective action

cause

IMPROPER ENGINE IDLING

Clogged

order

Incorrect idle

Clogged

or

Clean

damaged carburetor jets

Fuel system out of

Adjust

adjustment

manifold

element

Replace

air cleaner filter

Damaged

replace

or

gaskets

or

carburetor

Replace gasket

or

insulator

insulator

Adjust

Improper float level adjustment Loose air hoses

or

air fuel mixture hoses of

Check for loose connections

carburetor

Malfunctioning

carburetor choke

Check and

Malfunctioning

anti backfire valve

Check for loose connection of vacuum hose

Malfunctioning

automatic

temperature

con

adjust

Check A r C air cleaner

trol air cleaner Check for connection

Inoperative idle compensator

hose or

Carbon canister purge line hose damaged disconnected

or

tor

replace

Previously mentioned

compression

Others

Connect

or

of idle compensator

idle compen

Repair

Stick E F E valve shaft Low

replace

Incorrect valve clearance

Adjust

Extremely low revolution

Adjust

Faulty malfunction of the ignition system spark plug high tension cable breaker

Replace

point ignition coil

etc

Adjust

Incorrect basic ignition timing Malfunction of choke valve Malfunction of

vacuum

or

Adjust

linkage

motor

sensor

or

Check for loose hoses

hoses of air cleaner

ponents if necessary

Incorrect idle adjustment

Adjust

Clogged

Malfunction

of idle

compensator

of air

com

idle speed

Replace

air cleaner fdter

Replace system

air cleaner fdter

Replace

cleaner Malfunction of E G R control valve Loose manifold and

High engine idle speed

cylinder

head bolts

Clean

or

replace

Retighten

bolts

Dragged accelerator linkage

Check and correct accelerator

Incorrect idle adjustment

Adjust

Malfunction of B CDD system

Check for loose

linkage

idle speed vacuum

hose and harness

connections

Adjust Malfunction of speed switch and harness

Check

or

replace if necessary

for

loose

replace if necessary

ET 29

connections

Repair

or

Engine

Probable

Condition

Tune

up

Corrective action

cause

ENGINE POWER NOT UP TO NORMAL


Low compression

Ignition

system out of

order

iSnition

Incorrect

Adjust

timing

Damaged spark plugs

Clean

adjust

Worn distributor points

Dress

or

or

replace plull points

replace

Also

check

condenser

Fuel system out of

order

Malfunction of choke system

floating

Clogged

fuel pipe

Dirty

clogged fuel strainer

or

or

lst Adj valve

Clean

Replace Repair or replace

Fuel pump will not work properly

C10ssed

Disassemble and clean

carburetorjets

Check and replace

Malfunction of altitude compensator Air intake system of order

out

CIOJBed Ail

Replace

air cleaner from

inhaling

manifold

gasket

or

element

Replace gasket

carburetor gasket Emission control

Overheating

Malfunction of E G R valve

Check and replace

Stick E F E valve shaft

Repair

Insufficient coolant

Replenish

Loose fan belt

Adjust

Worn

Replace

or

oiled fan belt

Inoperative

Replace

thermostat

Replace

Worn water pump

Clogged

or

Flush

leaky radiator

Replace

Ail in

Retighten

cooling

system oil

Replace

grade

Clossed

Others

carburetor lean mixture

Connect

Inoperative thermostat

Replace

each part of cooling system

with proper grade oil

Improper

octane fuel

Replace

L

tire pressure

Inflate to

brake

Adjust

Clutch slipping

Adjust

Dragging

replace

Overhaul carburetor

Disconnected altitude compensator hOlle

j

or

Adjust

Incorrect ignition timing

cooIing

repair

Worn radiator filler cap

Improper engine

O

fan belt

with

specified

specified

octane fuel

pressure

Except transistor ignition

ET 30

system

Tune up

Engine

Probable

Condition

Corrective action

cause

NOISY ENGINE

Car knocking

Overloaded engine

Use

Carbon knocking

Disassemble

in driving

right gear

and

head

cylinder

remove

carbon

Mechanical

Timing knocking


Fuel knocking

Use

specified octane

Preignition misusing of spark plug

Use

specified spark plug

This strong dull noise increases when engine is accelerated To locate the place cause a misfire on each cylinder If the noise stops

This is caused

fuel

knocking

Crankshaft bearing

Imocking

by

the misfire

cylinder generates the

this

or

by

unevenly

bearings

and

worn or

adjust

or

damaged bearings

crankshaft

worn

change

Renew

crankshaft

Check lubrication system

noise

Connecting rod bearing knocking

This is

a

little

crankshaft

noise than the

higher pitched and

Imocking

is accelerated

also

Same

as

the

case

ofcrankshaft bearings

increases

Cause

a misfire engine noise deminishes and if the cylinder almost completely this crankshaft bearing

when on

each

generates the noise Piston and

cylinder

noise

Piston pin noise

This

revolution of engine and which decreases as is warmed up this noise is caused by

turn will cause a lower out

engine piston

and cylinder

cause a

misfire

This noise is heared at each

place

cause

This

noise

damaged

a

misfire

piston on

earings

or

by the

consumption

oil

Overhaul engine

highest

and

To locate the

by

worn

uneven

This may

or

cause

a wear on

piston pin

or

piston pin hole Renew

each cylinder

caused

be

may

excessive

put power and

of

place

To locate the

each cylinder

on

lowest dead end of

Water pump noise

of may cause an abnormal wearing which in cylinder and lower compression

When you hear an overlapping metalic noise which increases its magnitude with the

piston

Replace

and piston

pin assembly

water pump with a new one

surface

of sliding parts Air pump noise

Damaged air pump

Others

An improper

Repair or replace

adjustment

of valve clearance

Adjust

Noise of timing chain An excessive end

Noisy

Wear Note

play

on

clutch

This

clutch is

will

renew

main bearing

Repair

Renew bush and

pilot bushing

noise

the tension of chain

Disassemble engine and

crankshaft

E F E valve shaft

on

Adjust

be

heared

disengaged

ET31

when

adjust

drive shaft

Tune up

Engine probable

Condition

Corrective action

cause

ABNORMAL COMBUSTION backfue afterflre run on etc


Fuel system



Improper heat range of spark plugs

Use

carburetor

Damaged

out of

manifold

or

gasket

specified spark plugs them with

Replace

new

parts

backfue afterfire

order

Disassemble carburetor and check it

Cloled carburetor jet l

Improper Uneven

Run

idling

Others

etc

the level and check needle valve

Adjust

on

B CD D

Improperly adjusted

Faulty cylinder head

Adjust

function of the float

set pressure

Adjust

Malfunction of anti dieseling solenoid valve

Check or replace

Malfunction of

Adjust

choke auio

Adjust

valve clearance

Improperly adjusted

Excess carbon in combustion chamber

Remove head and get rid ofcarbon

Damaged valve spring backfire afterflre

Replace

a

new one

Malfunction of A T C air cleaner

Check for loose

vacuum

it with

hoses

Replace

if

necessary

Inoperative

backfue ariti

Loose oil drain

plug

Replape

valve

EXCESSIVE OIL CONSUMPTION Oilloak

Tighten

it

Loose

or

damaged oil pan gasket

Renew

gasket

or

tighten

it

Loose

or

damaged chain cover gasket

Renew

gasket

or

tighten

it

Worn oil seal in front and Loose

or

damaged

locker

rear of cover

crankshaft

Renew oil seal Renew

gasket

gasket

or

tighten

but

it

not too

much

Improper tightening

Renew

of oil filter

gasket

and tighten it with the proper

torque Loose

lo oil Excessi

consumption

or

Cylinder

damaged oil pressure switch

Renew oil pressure switch

and

Overhaul

pioton wear

Improper location of piston ring reversely assembled piston ring

piston ring groove

Fatigue

ofvalve oil seal

and ring

Inadequate quality Engine

renew

it

piston

Remoun t piston rings

Repair

or renew

Renew

piston

of engine oil

piston and cylinder

and

piston ring

seal

lip

with

Renew valve

or

guide

Replace

lip

Worn valve stem Others

or

and

tighten

Renew rings

Damage piston rings

Worn

gap

cylinder

or

Use the

designated

a

oil


overheat ET32

new one

Engine

Probable

Condition

the

xplanation

of the pow Oth

Corrective action

cause

FUEL ECONOMY

POOR Se

Tune up

r

dec

n

Exceeding idling revolution

Adjust

it to the

Inoperative acceleration

Adjust

it

recovery

designated

tighten

the

Fuel leakage

Repair pipes

Malfunction of B C D D

Adjust

Malfunction of A rC air cleaner

Check and replace

Inadequate oil quality

Use the designated oil

Overheat


or

rpm

connection of fuel

PROBLEM IN OTHER

FUNCTIONS D cr

d oil

p ssure

Worn oil pump

Disassemble oil pump and

regulator valve

Functional deterioration of oil pump

Repair or replace

Blocked oil f1lter

Renew it

Increased clearance in various sliding parts

Disassemble and

repair

it with

a

replace

the

or renew

it

new one

worn

parts with

new ones

Excessive

wear on

the

sliding parts

Blocked oil strainer

Oeanit

Inoperative oil

Replace

gauge pressure switch

Previousiy mentioned

Oil pressure decreases

Improper quality

or

Overheat

with

mentioned

Decrease of oil pressure

Previously

parts

Insufficient clearances

Readjust

Overheat

Previously

Improper fuel mixture

Check the fuel system

high

California only

Problem in fuel system tion of Fuel

Problem

in

one

Check the fuel system

mixture

Scuffing of sliding

Floor temperature too

proper


overcoal

Improper fuel

oil

element

Change element

air cleaner or

the

Exchange

contamination of oil

change Damaged

it with a new one

Refer to

Inspec

to the

designated

mentioned

Check and repair

System ignition system

Refer to

spection of Ignition System

ET33

In

Check and repair

clearances

and

SECTION EM

ENGINE

MECHANICAL


lMlSSAN I oJ

NISSAN MOTOR CO TOKYO

LTD JAPAN

GENERAL DESCRIPTION

EM

2

ENGINE DISASSEMBLY

EM

4

INSPECTION AND REPAIR

EM

8

ENGINE ASSEMBLY

EM 21


EM 2l


EM 31

SPECIAL SERVICE TOOLS

EM 33

Engine Mechanical

GENERAL DESCRIPTION CONTENTS EM 3

EM 2

CAMSHAFT

CYLINDER BLOCK

EM 3

VALVE

CRANKSHAFT

EM 3

CAMSHAFT DRIVE

EM 3

EM 3

MANIFOLDS

EM 3

MODEL

L20B

ENGINE

PISTON AND CONNECTING

ROD

EM 3

CYLINDER HEAD

dependable power The cylinder block is cast as

out smooth

MODEL L20B ENGINE

unit

aluminum head and

a

balanced 5 bearing crankshaft to

and

engine

The L20B engine features O H C valves combustion wedge shaped chamber

EM 3

MECHANISM

is

corporates

single

deep skirting This equipped with a single 2

featllres

carburetor that in

barrel downdraft

fully

CYLINDER BLOCK a

a

special

device to control

The

special

casting

emissions

employs

a

and higher durability

The cylinder bores

turn

a mono block

structure

support system for quiet

bearing five ness

block

cylinder

surrounded

are

by cooling jackets and machined di rectly in the block The oil ways in the block are arranged so that the full flow oil filter is directly attached to the right hand side of the block

EM536

Fig EM 2 Cylinder block

EM535

Fig EM Main

Cross sectional view

specifications L20B

Oisplacemen t

cc

cu

in

The

1191 952

1

CRANKSHAFT forging

Bore

x

stroke

3 35

x

Fully

smooth

85 X 86

in mm

crankshaft

39 3

is

dependable

ratio

8 5

Main bearings

MIT

pumped through

Non California model 750 10 California

AlT Manual Transmission

12 650 in

AIT

power at uses

model 0 position

Automatic Transmission

EM 2

are

high

eight balance

lubricated by oil

the main oil

and the oil holes which with

cylinder

run

bores There

gallery parallel

in

are

oilways

drilled in the crankshaft for the lubri

cating oil

equipped MIT

steel

turns out

weights

750 12 Ignition timing Degree B T O C rpm

it

speed The L20B engine

Compression

special

a

balanced

The center main

bearing

is

with thrust washers to take

up end thrust of the crankshaft

Engine Mechanical CAMSHAFT

CAMSHAFT

The camshaft is made of iron

cast

rocker

and

located

is

the

aluminum alloy

Four

cover

special

a

inside

brackets support it Camshaft bearings are lubricated from oil holes which lead Fig EM 3 Crankshafl

to

the

main

Concentric the

PISTON AND CONNECTING

two

rods

front and

through

rear

are

drilled in

parts of the

The connecting rods are of a special forged steel Oil is sprayed to the ends

an

shaft

a

double

by the crank

The tension

controlled

by

a

of the chain is chain tcosioner which

operated by spring and oil pressure The rubber shoe type tensioner damps is

tension

earn

lobe is

earn

plied

supplied

oil hole drilled in the base

Lubricant is sup

circle of each lobe to the front oil

gallery from the

2nd camshaft bearing and to the rear oil gallery from the 3rd camshaft

bearing

These holes on the base circle

of the lobe supply lubricant to the earn pad surface ofthe rocker arm and to the valve a

rod small

roller chain driven

vibration of the chain and controls its passages

Oil to each

compression rings and one combined oil ring The piston heads are slightly dished The piston pil1S are a special hollow steel shaft They are full floating fit to the piston and press fit to the connecting

connecting

gallery of the

The camshaft is driven by row

shaft

ROD

The pistons are of a special alumi num casting and have struts to control thermal expansion

oil

cylinder head

DRIVE

tip

end

The

profile

overlap long

cams

feature

to reduce NOx EM537

emission

Fig EM 8 Chain driving aystem

through

drilled passages in the large ends of rod Oil holes in the connecting rods located

are

so

as

to insure

optimum

lubrication under heavy load

0 5 01

Fig EM 6 Camshafl

The intake manifold is of an alumi

o

E Moao

Fig EM

4

num

Piston and connecting rod

VALVE MECHANISM The valve system has the rocker arms that are

CYLINDER HEAD The

MANIFOLDS

is

cylinder head

made

of

a

light strong aluminum alloy with good cooling efficiency it contains wedge A

type combustion chambers

special

pivot type activated directly

by the earn mechanism this has made its moving parts considerably lighter and provides ideal high speed perform ance

Dual

type

valve

springs

are

in

cast

alloy

The exhaust

manifold

design and incorporates valve

used A

face

to warm

is

of the

intake air out

pipe

is of a dual

heat control

The heal control valve is

in it

plate

a

the intake manifold installed manifold

through

on

the outer

to

draw

hot

it The exhaust

is connected to the

flanged

sur

face of the exhaust manifold

stalled

aluminum bronze valve seat is used on

the intake valve while steel

valve

seat

is

a

heat resistant

installed

exhaust valve These parts press fitted

are

on

the

all hot @l

h

if

EM407

Fig EM S

Cylinder head

Exhaust

Intake

EM084

Fig EM 7 Valve mechanism

EM 3

Fig EM 9 Intak

and exhaust

manifolds

r

Engine

I

Mechanical

I

ENGINE DISASSEMBLY CONTENTS PRELIMINARY CLEANING

AND

PISTONS

INSPECTION

4 EM

DISASSEMBL Y

I

gaskets

disassembling engine oil

crankshaft of

and

equipped

water

leakage

7

past

disassembling

and

block

check

Prior

cylinder

to

head

Remove starter motor from

Check carburetor and fuel pump for condition fuel hoses for deteriora

8

tion

chain

cracks

their jointed

or

trans

mission

Visually inspect cylinder head Ner front cylinder block rocker C

2 or water may leak past

head

cylinder

lInd

Remove air pump drive belt cool compressor and idler pulley if so

er

oil pan and oil filter

pump seals for signs their gasketed surfaces

note

following Fuel

EM 7 EM 7

6

front chain cover

INSt ECTION the

HE

RODS

AD

EM 4

PRELIMINARY CLEANING AND Before

AND CONNECTING

CYLINDER

leakage of fuel past

oil pan and all other outer

cover

for oil

parts

or connected surfaces

breakage

or

water

and fuel

missing parts such

leaks

as

bolts

and nuts 9 cuits

Check piping and electrical cir for deterioration breakage fit

tings discontinuity 1

1ltermal

2

Check valve

3

Altitude in

4

Air

Automatic

refer

I

11

E

valve relief valve

2

3

Installation

Remove

transmission

Remove

clutch

from

en

assembly

from

Thoroughly drain engine

oil and

Emergency air relief valve

coolan t by removing drain plugs Store engine oil and coolant if they

14

Air pump air cleaner

are

IS

Carbon canister

16

Air control

11

Air

solenoid valve 13

to be used

valve

I

Fig EM

0 Emiuion control devic

s

California mod 18

2

Remove carburetor air cleaner

Disconnect air cleaner to A B valve

Remove fresh air duct hot air duct from air

4

Disconnect

5

air

cleaner

to

related

Disconnect air cleaner to air pump hose at air cleaner

Loosen air cleaner band bolt and

Disconnect air cleanef to rocker

sembly

hose at rocker air

4

cover

cIeaner to air

remove

con

Plug

hoses at air cleaner

carburetor air cleaner

prevent entry of

foreign

5

alternator and alternator bracket

Remove

alternator

4 EM

to

matter

fornia models

drive

right engine mounting

Remove oil filter with Oil Filter Remove oil pressure swi tch Install engine attachment

alternator

bracket

Set

engine

Engine

on

and

stand

Attachment

ST05260001 belt

Engine Stand ST050I SOOO

to

bolt holes in

hole 6

trol valve hose at air cleaner Cali

only

as

from carburetor up carburetor air horn

cooling fan

Remove

cylinder block utilizing

part

vacuum

Remove

Wrench STI9320000

hose at air cleaner

cleaner

Disconnect

engine

bracket 3

cover

on

stand

pump

Disconnect

again

Place engine assembly

4

E T366

3

and

flywheeL

G R control valve B C D D control valve and

12

Removal

gine

Bee D D

P cv Air

vehicle

instructions under the

ER section

Anti 8ackfire valve A B valve Boost Controlled Deceleration

to

the

from

engine

remove

to

Engine

temperature control air cleaner

Device 9

To

gallery pipe

6 7 8

DISASSEMBLY

compensator air cleaner

choke Auto

insulation

valve

vacuum

S

or

water

drain

Mechanical

Engine

9

Remove

valve hose

block to P C V

from

block

cylinder 10

cylinder

blow by gas hose

Remove

manifold

attaching

bolts and remove intake and exhaust and

manifold

assembly cylinder head

1

Air control valve

2

Distributor

EM410

Fig EM

II

Engine

on

engine

Remove

carburetor from intake block

cylinder

Disconnect

to

Disconnect A B valve

to

E G R

passage hose at E G R passage 3 Disconnect vacuum tube to carburetor hoses vacuum

white and

yellow

at

fuel

3

carburetor

Disconnect

air cleaner

hose

vacuum

from

from

hose

4

Remove

check

valve

from

air

gallery pipe 5

Disconnect

E G R 6

tube

Disconnect

4

Remove

E G R valve

C V valve hose at P C V valve P 2

2

bracket

manifold

1

EM531

Fig EM 13 Removing air control valve Californio model

land

Remove oil level gauge 6

EG R

tube

passage and exhaust manifold E G R and passage

Remove

E G R valve from intake manifold

carburetor

bolts and remove carburetor and

and

exhaust

manifold attaching bolts and separate

Remove dash pot bracket from Remov

intake

Remove

11 intake

intake manifold 6

Fig EM 16 Removing intake and exhaust manifold assembly

from

carburetor 5

gasket from

manifold

from exhaust

mani

fold

attaching assembly

12

Remove air

gallery pipes from

exhaust manifold

gasket 12

Disconnect

distributor

sion cables from

sparkplugs

7

8

Disconnect

remove

ten

from

distributor

fuel

Disconnect

pump

and

hoses

combined

10 from

remove

from

fuel and

fuel

vacuum

14 I

E

G R passage

2

E G R

Fig EM

tube 14

EM532

Removing

E

G R tube and passage

assembly

pump

left

engi

from cylinder

Remove

air

mounting

e

blopk

pump

and

cooler

Remove

cylinder 8

F lC D

head if

so

Disconnect

thermal

vacuum

thermostat

crankshaft

pulley

in

washer and then stalling bolt remove pulley with a two jaw puller

bracket from

equipped

vacuum

valve

housing

and

hoses

and

from

remove

gasket from

assembly

15

Remove water pump

16

Remove rocker cover

17

Remove spark plugs

18

Remove fuel pump drive

19

Remove camshaft sprocket

head 7

Remove

and

from cylinder head fuel

Remove

cylinder

hose

Remove et

compressor bracket

as

sembly 9

bra 13

hose

vacuum

distributor and

high

earn

Refer to the following note during operation when removing camshaft sprocket from engine installed on car

cylinder head

EM412

Fig EM

IJ

Remove

12

Removing fuel

intake

and

pump

exhaust

manifold assembly from cylinder head

1

Disconnect

vacuum

hose

air control valve and remove air trol valve as an

for California

assembly

and

a r

from

EM089 EM091

con

hoses

Fig EM 15 Removing thermostat housing EM 5

Fig EM 17 Removing cammaf sprocket

r

Engine 28

Remove cylinder head

Use

Cylinder

STl0120000 bolts

Head

assembly

Bolt

to remove

Wrench

cylinder

Loosen bolts from

CD

to

Mechanical

29

Invert

30

Remove oil pan and oil strainer

36

engine

head

@

Remove piston and connecting mbly Extract connecting rod

rod

a

bearings keeping

them in order

as

shown in Figure EM 18

EM094

Fig EM 20 Removing oil

I

traintir

Fig EM 23 Removing pilton and connecting rod aatm b y

and oil pump

Fig EM IS Cylinder head bolt

loosening

equence

31 Notes

When

removing cylinder

from engiJJe installed

on car

heao

follow

the instructions below a

Turn crankshaft until No TD C

is at

on

its

I

pilton compression

Remove oil pump and its drive

spindle

See Figure

32

Remove front

33

Remove

37

Remove flywheel and

Be careful

EM 20

not

to

drop

rear

plate

them

cover

chain

tensioner

and

chain slack side guide

stroke b

Remove

c

pump To facilitate scribe

8

rocker

Cover

assembling on timing

mark

and

o c

fuel tion

8in and

camshaft sprocket with paint be fore removal d Loosen camshaft bolt and fuel pump drive e

EM415

remove

Fig

earn

EM 24

Removing flywheel

Support timing Chain ween

chain by utilizing Stopper STl7420001 bet timiilg chains as shown in

Figure This

0

EM095

38

EM 19

peration eliminates the prob

lem of

realigning timing

chain timing sprocket

and

marks

Fig EM 21 Removing chain ten ioner and tim ing chain

on

crankshaft

Remove main bearing caps Use Crankshaft Main

Puller KVIOI04ISO to and

rear

Bearing Cap

remove

main bearing caps

center

Keep

them

in order 34

Remove

Figure EM

timing

chain

See

2l

35

Remove oil thrower crankshaft

wonn

gear and chain drive

sprocket

KVIOI04IS0

EM539

Fig EM 25 Removing rear main bearing cap

EM538

Fig EM 19 Supporting timing chain

f Remove camshaft sprocket Loosen cylinder head bolts and

g

remove

39

Fig EM 22 Removing chain drive

cylinder head

Proc

6 EM

et

main

40

Remove two side seals from

bearing

ca

Remove

p

rear

oil seal

rear

Engine Mechanical Be careful

Note

not to

shaft bearings and

3

Remove valves

earn

damage

eam

lobes

using Valve Lifter

STl2070000

EM103 EM411

STl2070000

Fig EM 29 Remouingpi tonpin

Fig EM 26 Remouing rear oil eal 3 41

Remove crankshaft

42

Remove

baffie

plate

Keep

disassembled parts in order

and cyl

inder block net

CYLINDER HEAD I

Remove

valve

rocker

Fig EM 32 Removing ualves

springs

Loosen valve rocker pivot lock nut and remove

rocker

arm

by pressing

valve

spring down Notes a

Take care not to lose valve seat oil seal valve collet

spring

and valve

rocker guide b Be

sure

keep camshaft bearings bearing center is liable out of alignment to

intact or the

Fig EM 27 Removing baffle plate and

to come

nel

PISTONS AND CONNECTING RODS Remove

piston rings with

a

61 8

ring

Fig EM 3D Removing rockerarrm

remover

2

Remove locate

plate

and

remove

camshaft

O

Exhaust

Fig EM 28 Removing pilton rings

Press

piston pin

EM105

out with Piston

Pin Press Stand STl3030001

EM101

Fig EM 33 Value components

EM102

2

Intake

Fig EM 31

Remouing cammaft

EM 7

r Engine

Mechanical

INSPECTION AND REPAIR CONTENTS PREPARATION CYLINDER

FOR

INSPECTION

HEAD AND VALVE

CHECKING CYLINDER

VALVE SPRING ARM AND VALVE

CAMSHAFT

CAMSHAFT VALVE

INSERTS

AND CAMSHAFT

BLOCK MEASURE

CYLINDER

CYLINDER

Before

BORE

BORING

cleaning

check for

Note

Clean

oil

carbon

sure

that

EM

8

BUSHING AND BEARING

EM

9

EM 16

MEASUREMENT

OF

EM 17

MAIN

BEARING EM 17

EM lO

MEASUREMENT OF CONNECTING

EM l0

BEARING

EM 11

FITTING

ROD

CLEARANCE

EM 1B

BEARINGS

EM 18 EM 19

MISCELLANEOUS COMPONENTS CRANKSHAFT AND CAMSHAFT

EM 12

SPROCKETS

EM 13

CHAIN TENSIONER AND CHAIN

EM 13

FLYWHEEL

EM 13

FRONT COVER

deposits

camshaft bear

remove

unless

machine

or

ing in line

have

you

boring

a

EM 19 EM 20

GUIDE

EM 20 AND

REAR OIL SEAL

EM 20

Head surface flatnes

Suitable

Camshaft bear

If you

once

camshaft

Standard

remove

bearings bearing will come out o alignment reo conditioning is very difficult with out center borings

and

sealant from an parts Remove gasket 3 Clean all oil holes with solvent and dry

EM 16

CRANKSHAFT

Never

ings

signs

of water and oil leaks in cylinder block and head 2

EM 15 ROD

EM 14

PREPARATION FOR N INSPECTI I

AND

8

EM 12

BEARING CLEARANCE

TIMING

HOW TO

PINS

EM

EM 12

BEARING

CAMSHAFT ALIGNMENT CYLINDER

PISTON

CLEARANCE

VALVE GUIDE SEAT

PISTON RINGS

ROCKER

PIVOT

VALVE

PISTONS

B

CONNECTING

ASSEMBLY

ROCKER

8

EM

HEAD MATING

FACE VALVE

EM

Maximum

centers

less than 0 05 mm

O lmm

0 0020 in

0 0039 in

with compressed air Make

they

are

L

not restricted

Make a

v

isual

check for cracks

and flaws 2

Measure

head

on

warpage

the surface of cylinder block side for

If it is found to be

beyond regrind the

the limit designated below affected surface with a surface grinder

CYLINDER HEAD AND VALVE

VALVE ASSEMBLY

cylinder

Check each intake and exhaust valve for

worn

damaged

or

deformed

valve caps or stems Correct any valve that is faulty

or

2

stem

Valve

face

valve

or

surface should be refaced with

CHECKING CYLINDER HEAD MATING

replace

a

end

valve

grinder

FACE

10 L

I

I

I EM109

EM407

Fig EM 34 Cylinder head

Fig EM 35 Checking cylinder head 8JJrface 8 EM

Fig EM 36 Intak

and exhaust valve dimensions

Engine Mechanical VALVE SPRING H

Valve head diameter mm

I

in

Valve length

L

mm

in

In

42 0 to 42 2

1 654 to 1 661

Ex

35 0 to 35 2

378 1

In

114 9 to 115 2

Ex

1157 to 116 0

1 Check valve spring for squareness using a steel square and surface plate If spring is out of square more than

to 1 386 524 4 555 4

to

4 535

1 6 mm 2

to 4 567

sion

D

mm

a

In

Valve stem diameter

7 965 to 7 980

3136 0

to

0 063 in

Measure

lhe

of each spring

value exceeds

0 3142

replace length

free

and ten

If the measured

specified

limit

replace

spring

in

Valve seat angle Intake and Exhaust

Ex

7 945 to 7 960

In

45030

Ex

45030

3128 0

to

3134 0

I i

T J

EM112

Fig EM 39 Measuring spring

quareneu

EM110

Fig EM 37 Checking valve

tern EMll1

diameter

Fig EM 38 Regrinding valve face Note

When valve head has been

down to 0 5

nun

1 worn

0 0197 in

in

thickness replace the valve Grinding allowance for valve stem end surface is 0 5 or

mm

EM113

0 0197 in Fig EM 40 Measuring apring

less

ten

Spring specifications Valve spring free length

mm

in

Intake and exhaust

Outer

49 98

Inner

44

Valve spring pressured

1 968

1 85

766

length

valve open

mmlkg

in lb

Intake and exhaust Outer

29 5 49 0

Inner

24 5

Valve spring assembled height valve close

mmlkg

161 1

108

5 0 965156 2 25

in lb

Intake and exhaust Outer

40 0

Inner

35

EM 9

12 0

3 21 3

1575 47 0 1378 27 I

ion

rr Mechanical

Engine ROCKER ARM AND

Replacement

VALVE ROCKER PIVOT

8 3 to 8 5 dia

Exhaust

0

Check pivot head and cam contact and pivot contact surfaces of rocker arm

for damage

found

faulty pivot replace must be replaced together with its corresponding rocker arm A

3 0

1

If clearance

223 to 12 234 0 4812 to 0 4817

dia

6 to 7 8 0 299 to 0 307

1

Unit

designated limit replace worn parts or both valve and valve guide In such

from

combustion

rocker

cover

cylinder head side guide temperature

room

mm

in

Fig EM 41 Se11Jice value guide

10 6 0

In take valve 0 020

or

dia

valve guide

in

out

side toward

Ream

hole at

worn or

mm

drift

EM572

it is essential to determine if

Stem to guide clearance

a

use

2 ton pressure

operation 2

clearance has been caused by a bent valve stem or by a worn

a

them

7

0 425 8 S9 0 2 323

a

Heated cylinder head will facilitate the

P 10

old guides

under

guide

hammer

chamber

exceeds

this case

remove

Drive

JL

I

J

between valve

and valve stem

guide

150

Intake

VALVE GUIDE clearance

a

12

I Measure

I2

To

and a press

1 4

If damage is

or wear

them

I

327 to 0 335

of valve

to

E lj m3l

10 6

dl7 IV

Exhaust valve

0 053

5t

e

l

0 040 to 0 073

0 0008 to 0 002

417

flH O II

0 00 6 to 0 0029

Maximum limit ofabove clearance

mm

01

in

0 0039

Unit

mm

in

EM116

Fig EM 43 Valve guide hole

As an emergency can

expedient

be pushed into valve

moved

to

the

more

it

valve and

and left If its

right

deflects about

a

guide

2 mm 0

00079 in

tip

For factory standard

or

indicates that the clearance

between stem

Guide hole inner

and guide exceeds the of 1 mm 0 0039 0

diameter

an

4718 0

For service valve

in

guide Valve should be moved in paral

lel with rocker

large

arm

Generally

a

amount of wear occurs in this

direction

3

n

mm

0 0079 in

r l 18Iin 30mm

new

valve guide

smoothly

after

to 150 to

heating cylinder

2000C 0 2

press

into valve so that it will fit

302

to

head

12 185 to 12

4797 0

Reaming

to

96

4802 0

bore

8 000 to 8 018

3150 0

rnm

to 0 3157 in

3920 F

Valve guide of 0 2

Max allowable deflection

C1r

Carefully

to 0 4723

in

mm

maximum limit

Note

11985 to 11996

valve guide

oversize

mm 0 0079 in diameter is available for ser

vice as indicated above

Interference fit of valve

r

guide

to

guide hole

0 027

to

0 049

mm

0 0011 to 0 0019 in

EM115

Fig EM 42 Mea uring clearance between valve tern and valve gu ide

4

Ream bore with valve guide press using Valve Guide Reamer Set

ed in

KVIOI039S0

EM419

Fig EM 44 Reaming valve guide EM 10

Engine Mechanical valve seat surface with

5

Correct

new

valve guide

as

the axis

1

Old insert

boring

machine

VALVE SEAT INSERTS

of pitting at valve contact or replace if worn

evidence

ert

be removed by

can

collapses The should be set so

until it

out

depth stop

that boring cannot continue beyond the bottom face of the insert recess in

valve seat inserts for any

Check

it

eat In

valve

Replacln

cylinder head

surface and reseat

2

excessively

and check its outside diameter

Valve seat insert of in

5 0

mm

0 0197

3

Fig EM 45 Correcting valve

oversize is available for service as

seat

shown below

the

Select

a

suitable valve seat insert

Machine

cylinder head

concentric

center

so

recess to

circles in valve

that

guide

insert will have

the

correct fit

4

Heat cylinder head to

ture of 150 to 2000C q

lO

1

k k

Intake

5

I

the

I

i 37

0 mm

597 45 1 7 95

in

EM573

0

32 6

Exhaust

12835

Unit

mm

I

14795 to 14802

dia

in Fig EM 46 Seroice valve seat dimensions

Cylinder head

rece diameter

For factory standard

Unit

45 000

to

500 45

to

mm

in

45 016 1 7717 to 17723

insert

Intake For service insert For

factory standard

insert

1 7913 to I 7920

516 45

37 000 to 37 016

1 4567 to I 4573

37 500 to 37 516

1 4764 to I 4770

Exhaust

I

For service insert

Interference fit

mm

0 0032 to 0 0044

Intake

0081 to 0 113

Exhaust

0 064 to 0 096 0 0025 to 0 0038

in

recess

and

than 4 points

clean valve and valve

0 295

U81 dia

37 580 to 37 596

it beds on

against its seat until proper valve seat ing is obtained Remove valve and then

dia

5 17

I 30

of its

Newly fitted valve seats should be cut or ground at the specified dimen 47 EM sions as shown in Figure 7 small amount of fine grind Apply to valve contacting face ing compound and put valve into guide Lap valve

dis

45 613 1 796 dia

to to

more

ensuring that

face

tempera

6

co

Unit

bottom

caulk

9 to 38 1 1492 to 1 500

eel q

Fit insert

a

302 to 3920 F

EM 11

sea 1

Engine Mechanical

I

600

Intake

38

W 45 Unit

mm

1 496I dia

39 6 I559Ildia 18 16457 dia 71l1 1

in

30

Exhaust

I

811 di 30 l1 32 6 2835 dia 34 6 1 3622 dia

137 1 4567

dia EM121

Unit

mm

m

Fig EM 47 Standard value

CAMSHAFT AND CAMSHAFT BEARING

aeat

dimensions

VALVE TIMING This

CAMSHAnBEARING CLEARANCE

carn

Measure

inside

diagram

applies

to

all

cyl

inders If any valve is found out of that specifications one possibility

diameter of

lobe is

worn or

This

damaged

calls for replacement of camshaft

earn

haft beating with an inside dial gauge and outside diameter of camshaft jour nal

with

a

micrometer

found inside of bracket inder head

If

wear

is EM119

replace cyl

Fig EM 48 Checking cam haft bearing

assembly

Camshaft journal to bearing clearance Standard

Oil clearance

mm

in

0 038 to 0 067 0 0015

to

0 0026

Wear limit

0 1 0 0039 B DC

Inner diameter of shaft

bearing

mm

earn

in

48 000 to 48 016

EM421

18898 to 18904

Fig EM 49 Value timing diagram

EM 12

Engine Mechanical j Bend limit

Standard

Using

round

of out

Camshaft bend mm

0 02

bore

0 05 0 0020

0 0008

I

in

a

bore

measure

gauge

cyl

inder bore for out of round or taper If or

cylinder

machine

taper is excessive re walls with a boring should

Measuremen t

be

taken along bores for taper and around See Figure bores for of round out CAMSHAFT ALIGNMENT

EM 52

I

Check camshaft camshaft journal

and

earn

surface for

bend

wear

or

damage If damage is beyond limits replace affected parts

Qu t of round

X Y

Taper

A B

A bend value is one half of the

2

reading obtained turned

one

applied

gauge

when

camshaft

full revolution with to 2nd and 3rd

a

is

dial

journals

Fig EM 50 Checking camMa

t

bend M12

Fig EM 52 Measuring cylinder bore diameter

Standard height of tam

mm

in

I

Intake

1

Exhaust

to

30 40

35 40

1 5866 to 1 5886 4

When

wear

taper

or

out of round

is minor and within limits remove step Wear limit of earn

height

mm

in

0 25 0 0098

a

able difference in diam Allo max worn and min

ter

betweim worn

topmost portion of cylinder using ridge reamer or other similar tool

at

mm

in

0 05

mm

in

0 1

00020

parts of c mshaft journal

Maximum

tolerance

in

irri j01

0 0039

diameter

CamShaft

end

mm

play

in

Surface flatness in

0 08 to

38 0

0 0031 to 0 0150

A bore gauge is used Measure cylind r bore at top middle and bot tom positions toward A and B direc tions as shown in Figure EM 53 and

Standard

mm

TO MEASURE CYLINDER BORE HOW

Maximum tolerance

less than 0 05

0

0 10

0020

record the measured values

0 0039 A

I

120 0 79

IlL 60 2 36

B

100

el

lll

3 1

94

Cy LlNDER BLOCK I

Visually check cylinder block for

cracks 2

or

flaws

Measure

top of cylinder block

head mating face for warp age If warpage exceeds limits correct

cylinder

it

EM

22

r

Unit

mm

m

EM540

Fig

EM 51

Cheching cylinder block au rface

EM 13

Fig EM 53 Cylinder bort me08Uring positions

Engine Mechanical

Standard

Wear limit

85 000 to 85 050

Inner diameter

3465 3

to

0 2 00079

3484 3

Cylinder bore Out of round

in

mm

ot5 O

0 015 00006

Taper Difference in cylinder bore

0 05

in

mm

00006

0 0020

0 2 0 0079

CYLINDER BORING I

When any cylinder needs boring all other cylinders must also be bored at

2

Determine

cording

piston

to amount

oversize

L

ac

of wear of cylinder

aboull

Oversize pistons spec Hicetlons

Piston diameter

mm

6

7

A

the same time

o 7323in

m

r

in

127

84 985 to 85 035

Servioe standard

3459 3

Fig EM 55 MeCUJlJring piston skirt diameter

to 3 3478

Rebored size calculation

0 50 0 0197

85 465 to 85 515

Oversize

3648 3

o

to 3 3667

1 00 0 0394

3844 3

C

0005 to

A

0 0002 to 00010 in

mm

where

85 965 to 86 015

oversize

B

A

Q25 0

D Honed diameter

to 3 3864

A Skirt diameter as measured

3 be

The size to which cylinders must is determined by adding clearance

cylinder to

largest piston

diameter

at

to

Piston to wall clearance

C

Machining

Standard clearance

f im in

0 025 to 0 045

piston skirt

Feeler gauge

mm

Extracting

kg Ib

in

force

Notes a

To prevent strain due to heat bore the

cutting

cylinders in the order

of 241 3 b

0 2 to 1 5

Before

be honed to size 7

boring any cylinder install bearing caps in place and tighten to the specification so that the crankshaft bearing bores will

8

not become distorted from the bor

ance

Measure

bore for

Measure

This

the

of out

Do not

cut

cylinder bore at mm

Measuring piston diamet r

00020 in

a

too

much out of

time Cut only 0 05

or so

time

EM 14

in diameter at a

finished

round

piston

clearance

easily by using 4

O 44 to 3 31

5 Measurement of a just machined cylinder bore requires utmost care since it is expanded by cutting heat 6 As a final step cylinders should

main

ing operation

EM 54

mm

004 0 0016

in thrust direction

Fig

0 02

0 0010 to 0 0018

the

EM126

allowance

0 0008 in

honed

piston

B

or

to

can

cylinder

tapered

part

cylinder clear be

checked

feeler gauge and a spring balance hooked on feeler gauge measuring the amount of force re

quired piston

to

a

pull gauge cylinder

and

out from

between

Engine Mechanical Notes a

PISTONS PISTON PINS AND PISTON RINGS

When

measuring clearance slowly pull feeier gaUge siraight upward

b It Is reConUnended that piston and

cylinder

hel ted

be

to

200C 680F

I

Remove carbon from piston and a ca bon scraper and

grooves with

ring a

curved steel wire

Clean out oil slots

in bottom land of oil 2

Check for

wear

I

Replace

3

ring

damage

00

groove

scratches and

if necessary

side clearance of rings in ring grooves as each ring is installed Side clearance should be as follows 1re Meas1

EM542

Fig EM 58 Measuring ring gap Notes

t

a

J

f

rr

piston ring only is to be replaced without cylinder bore being corrected measure gap at bottom of cylinder where wear is minor

1

11

When

I

b Oversize EM541

piston rings

are

available

for serv ce

Fig EM 56 Measuringpiaton fit in cylinder

Oversize mm

0 0197 in

10 mm

0 0394 in

05 Fig EM 57 Measuring piston ring side clearance

5

and

Measure piston pin hole in rela pin If wear

tion to outer diameter of

exceeds limit replace each piston pin together with the piston on which it is

Side clearance Unit

mm

in

installed 6 Standard

Top ring Second ring

Oil ring

f

4 ton

I I I

0 040

0 073

to

0 070

to

0 0012

to

cylinder

place it measure ring

as

to

with

of piston

must be a

0 0039

tight

pre

This s

piston pin

fit into connect

ing rod

I I

feeler gauge

Ring should be placed

in

squarely gap

0 0028

fitting

temperature

room

01 0 030

Determine the into

piston pin hole to such an extent that it can be finger pressed at pin

0 0016 to 0 0029

Push ring into cylinder with pis so

Wear limit

at upper

a

or

to

diameter

lower limit of ring travel EM131

Ring

gap

Unit

Standard

Top ring Second ring

0 25 to

rom

in

Fig EM 59 Piston pin fitting

Wear limit

40 0

0 0098 to 0 0157 30 0

to 0 50

0 0 II8 to 0 0197

1 0 0 0394 EM132

Oil ring

0 30 to 0 90 Fig EM 60 Measuring pi ton pin

0 0118 to 0 0354

diamet

EM 15

r

Engine

Mechanical Unit

Piston pin outside diameter

20 993 to 20 998

mm

in

CRANKSHAFT 1

0 8265 to 0 8267

Whenever crankshaft

from Piston pin hole diameter Piston pin

21001 to 21008

piston clearance

to

I

0 003 to 0 015

to

thoroughly cleaning check crank

0 006

Rep

If damage 0 015 to 0 035

0 0006 to 0 0014

connecting rod

crankshaft

pin Jor

cracks

Interference fit of piston

pin

to

engine

is removed be

should

cleaned

in a suitable solvent

0 8268 to 0 8271

00001

it

crocus

is

bias

score

air or

replace

minor

After

journal and wear

or

required

as

dress with fine

cloth

2

Check journals and crank pins for taper and out of round with a micro meter Measurement should be taken

along journals journals for

CONNECTING ROD If

I on

connecting rod has

a

any flaw

either side of the thrust face

large

end correct or

replace

or

2

the

Check connecting rod for bend

torsion

it

using

If bend q rrect

or

or

a

connecting

rod

63 EM

or

or

torsion exceeds the limit

of out

with

replace

round

of out

See Figure

for detailed information

Ifjournals

aligner

for taper and around

a

or

crank

pins are tapered

round beyond limits

replace

shaft

new

A

B

EM133

Fig EM 61 Ch cking rod alignment

Standard

Connecting

Maximum

Out of round

XY

Taper

AB

rod bend Unit

per 100 mm in length

torsion

or

3 94

or

0 03 0 0012

0 05

19 5

0 0020

30 181

in mm 43

3

27 106

tt

and old

new

ones

and

1

E

is within 7

oz

All main

Do not use a combination

of

new

former

2

connecting rod big end connecting rod bolts which affect specified weight variations 4 Install connecting rods with bear ings on to corresponding crank pins measure

thrust clearance

ured value exceeds limit

Ifmeas

replace

end

play

mm

in

3599 l

o

2

3604

All crank pm

49 961 to 49 974 1 9670

to

19675

EM424

Fig

EM 63

Crankshaft and journal dimensions

Fig EM 62 Checking big end play

Standard

Big

journa

59 942 to 59 955

nuts and

and

32 1 2 60

I

replacing connecting rod select rod so that weight difference gr 0 25

in

l 69 O

When

between

mm

0 768

Maximum

0 2 to 0 3 0 0079 to 0 01 18

0 6 0 0236

EM 16

Engine Mechanical Maximum

Standard

STl6610001

Taper and

out

of round

less than

of journal and crank pin

0 0010

Q25 0

0 0004

in

mm

3

0 01

Crankshaft bend

by placing

using a indicating finger

dial gauge with its

resting

be checked

can

it on V blocks and

EM425

Fig EM 66 Pulling

center journal

on

outpilot

bushing

2

Before

thoroughly

installing

a

new

bushing

clean bushing hole

Press

fit

bushing so that its height above 5 to 5 0 mm 177 0 to flange end is 4 0 197 in Do not oil bushing EM137

bend Fig EM 64 Checking crankshaft

Maximum

Standard

less than Crankshaft bend

mm

in

0 10 0 0039

0 05 0 0020

EM418

Note

measuring bend

When

use

a

Fig EM 67 Press fitting

dial gauge Bend value is half of the reading obtained when crankshaft is turned

one

full revolution with

dial gauge attached

to

its

a

center

BUSHING AND BEARING

After regrinding crankshaft finish

it

to

the necessary size indicated

on

MEASUREMENT

by using an adequate bearing according to the

EM 18

page undersize

extent of 5

crankshaft

block and

measure

I in

OF

MAIN BEARING CLEARANCE

required repair

Install

pilot

bush ng

journal 4

new

cylinder

Thoroughly

clean all bearings and

check for scratches

crankshaft free end

Fig EM 65 Checking crankshaft end play

play

melting

score

or

if any

fault

is

wear

Replace bearings detected 2

Wear limit

Standard

3

Crankshaft free end

play

6

mm

At

check wear or

in

the

rear

0 05

to

0 0020

is detected

to

03

for

4

00118

0 0071

To

end of crankshaft

pilot bushing damage Replace it if any fault

crankshaft

0 18

replace

crankshaft

bushing proceed

I

Pull

out

as

rear

pilot

follows

bushing

using Pilot

Bushing Puller STl66 1000 I EM 17

Crankshaft

journals

and bearings

should be clean and free from dust and dirt before oil clearance is measured Set main bearing Cut

a

on

cap block

plastigage to width of bear it in with crank

ing and place parallel pin getting clear of the oil hole Install them cap on the assembly and tighten together

to

the

specified

Tightening torque 5 kg m 5 to 4

torque

33 to 40 ft lb

Engine Mechanical Bearing 011 clearance Wear limit

Standard 0 020 to 0 062

Main bearing clearance

0 0008 to 00024

in

mm

0 025 to

Connecting rod bearing clearance

mm

055 0

0 0010 to 00022

in

0 12

0 0047

0 12

0 0047

Fig EM 68 P14stigage

2 Note

tum crankshaft

Do not

plastigage

is

while

being inserted

Remove cap and compare width of the plastigage at its widest part with

3

Then

value

If clearance

replace bearing with an under size bearing and grind crankshaft jour

with

a

nal

listed below

exceeds

specified

measure

bearing

crush

H

feeler gauge See Figure EM 70 The standard bearing crush value is

adequately

5

scale

the

printed

in

plastigage

FiniNG BEARINGS

enve

lope

Bearings crush

to

its bore

manufactured

are

with

make bearing snug down into To measure this

proceed

Weight

as

H

follows I

cap

Set main bearing in main recess or cylinder block

recess

2

bearing bearing

correctly

Lock

one

side of bearing and

press other side until bearing back surface touches the recess

Fig

EM 70 Checking bearing crum

Bearing crush All main

Fig EM 69 Measuring bearing

bearings

mm

in

mm

in

o to 0 03 0 to 0 0012

clearance

All connecting rod

MEASUREMENT OF CONNECTING ROD BEARING

4

bearings

0015 to 0 045

Handle connecting rod bearing in

the

0 0006 to 0 0018

same manner as

above

CLEARANCE I

Measure connecting rod bearing same manner as above

clearance in the

Main bearing undersize

Tightening torque 4 5 to

5

kg

m

Unit

Bearing top

33 to 40 ft lb

1 827 to 1835

SID

0 25

00719

00098

Undersize

50 0

to

0 0722

1952 to 1960 0 0769 to 0 0772

0 0197

2 077 to 2 085 0 0818 to 0 0821

Undersize

0 75

thickness

00295

2 202 to 2 210 00867 to 0 0870

Undersize

EM 18

mm

Crank journal diameter 59 942

to

59 955

2 3599 to 2 3604

59 692 to 59 705 2 3501 to

59442

to

3506 2

59 455

2 3402 to 2 3407

59 192 to 59 205 3304 2

to 2 3309

in

Mechanical

Engine Connectlns rod be rlns undersize

Unit

Bearing top

thickness

506 1493 to 1

SID

0 0098

Undersize

1 618 to 1 631

0 0637 to 0 0642

0 50 0 0197 Undersize

0 75 0 0295

Undersize

1 743 to 1 756

0 0686 to 0 0691 1 868 to 1 881

0 0735

to

Crank pin diameter

49 961 to 49 974

0 0588 to 0 0593

0 25

0 0741

1 9670 to 1 9675

49711 to 49 724 1 9571 to 1 9576

49461 to 49 474 1 9473 to 1 9478

49 211 to 49 224 1 9374 to 1 9379

MISCELLANEOUS COMPONENTS CRANKSHA CAMSHA

SPROCKETS

Replace

sprocket

or

tion

wear

or

stretch

at

exces

roller links

sprocket is preset at hole at the factory If chain becomes loose adjust it by setting camshaft sprocket at NO 2 hole If chain is too loose adjust it by setting camshaft sprocket at No 3 hole Camshaft

found 2

Check chain for damage

sive

location holes Nos I 2 and 3

fault is

if

3

Replace if faulty 4 To properly adjust chain tension or valve timing camshaft sprocket has a earn locating plate and three

AND

Check tooth surface for flaws

I wear

in

mm

Install camshaft sprocket in posi and check for rounout If it 0 1

exceeds

mm

0 0039 in

indicator

No I Fig EM

total

72

Checking camshaft end play

camshaft

reading repl sprocket Also check for end play ce

Camshaft end play 0 08 to

38 0

mm

0 0032 to 0 0150 in

Location

match

2 3

3 EMl48

Before adjustment

Fig EM 71 Checking eam haft sprocket Tunaut

After adju5tmen t EM311

Fig EM 73 Adjuating camshaft aprocket location

EM 19

Engine Mechanical Turn

I at

T DC

Determine

engine until No I piston is its compression stroke whether camshaft sprocket

on

location notch of the

comes

oblong

locating plate

CHAIN TENSIONER AND CHAIN GUIDE Check for

off the left end

groove

on

camshaft

place

wear

and

breakage

Re

if necessary

If the location notch is

off the left end of the oblong groove chain stretch is beyond limits

EM426

Fig

EM 76

Checking flywheel deviation

40150

3

r

Check tooth surfaces of ring gear

for flaws

I

or wear

Replace

if necessary

FRONT COVER AND

L

REAR OIL SEAL First check front

EM147 EMl46

Fig

EM 75

Cam haft dri

mechanilm

Fig EM 74 Camshafllocating plate

rear

oil

seal for worn or folded over sealing

lip

or

oil

leakage

If necessary

seal When installing

new

It is

good practice

seal whenever

2

its

camshaft

setting

compression on

be used

3

a

The

amount

of the modifica

40 rotation ofcrankshaft

When modification becomes im

possible

even

location hole

by transferring camshaft replace chain assembly

a

seal

to

replace

oil

is overhauled

r

No 2 location

of the oblong groove When No 2 hole is used NO 2 timing mark must also

a new

r

stroke

hole in camshaft sprocket This No 2 notch should then be on the right end

tion is

engine

Turn engine until No I piston is on

install

pay attention to mounting direction Note

at T D C

cover an

Frant

FLYWHEEL I

Check clutch disc contact surface

with

flywheel for damage Repair or replace if necessary

2

t

Measure

runout

or

of clutch

wear

Front

disc

contact surface with a dial gauge fit exceeds 0 15 mm 0 0059 in total

indicator reading

replace it

EM 20

JI Real

EM150

Fig

EM 77 Oil

eals of crank haft

Mechanical

Engine

ENGINE ASSEMBLY CONTENTS PRECAUTIONS

EM 21

PISTON

CYLINDER

EM 21

ENGINE

HEAD

PRECAUTIONS I

Use

cleaned

thoroughly

Especially

Cylinder

block

as

s uIe

apply engine

to

Ill

s e

oil

00 000

to them 3

Use new

4

Do not reuse lock washers

5

Keep tools

and oil seals

packing

o Points to be

6

Keep

near

at hand

7

Be sure to follow

necessary parts

and

applied sealant

EM151

Fig EM 79 Applying sealanl Main bearing cap and cylinder block

work benches

and

clean

Fig EM 81 Installing valves Notes

tools

Ensure

a

specified tight

ening torque and order 8 Applying sealant Use sealant to eliminate water and oil leaks Parts

I

EM 22

20to2Smm

When installing sliding parts such be

EM 22

parts

make sure that oil holes are

bearings

ROD

ASSEMBLY

Rear main bearing cap

clear of foreign matter 2

AND CONNECTING

requiring sealant

are

Front cover and corners of cyl

Cylinder block

3

Step portions

at

four mating surfaces cylinder block to front chain cover and cylinder block to

rear

bearing

main

that valve face is free from

foreign matter b The L20B engine

uses

double type

valve springs

See Figure

cap

2

EM 80

Valve rocker pivot assembly valve rocker pivots joined

Screw Note

Do not

apply

too much sealant

inder block See Figure EM 78

with lock nuts into pivot hushing 3 Camshaft assembly Set

locating

plate

and

carefully

install camshaft in cylinder head

J

Do

damage the bearing inside Oblong of locating plate must be groove not

directed toward front side of engine Camshaft bracket tightening

torque 1 8 to 2 0 4

Apply

sealant at

hese

points EM152

Fig EM 80 Applying sealant Cylinder block

EM153

Fig EM 78 Applying Front

alant

cover

cylinder

and

kg in 13

to

15 ft lb

Install camshaft

shaft and

tighten

it

pump drive cam to

sprocket on earn together with fuel specified torque

Tightening torque 12 tol6 kg this time

m

87 to 116 ft lb

check camshaft end

block

CYLINDER HEAD Valve assembly and valve spring Using Valve Lifter STl2070000 set valve pring seat in position and fit valve Main bearing cap and cylinder block Each side of rear main bearing 2

cap and each

corner

See Figure EM 79

of cylinder block

guide

with oil seaL

Assemble valve in the order shown below

springs

valve

inner

spring

and valve rocker

and outer valve

retainer

guide EM 21

valve collet

Fig EM 82 Installing camshaft

sprocket

Engine Mechanical Install

5

rocker

arms

by pressing

b Arrange

valve springs down with a screwdriver 6 Install valve rocker springs

assembling cylinder head camshaft until No I piston is at

After

7 turn

T D C

on

its

that oil

so

jet

of connect

ing rod big end is directed toward right side of eylinder block Be

c

sure

to install

piston in cylinders mark of piston head

with notch

compression stroke

toward front of engine 2

Notes a

EM1S5

c

as

lower

c

Assemble pistons piston pins and

connecting cylinder

on

a

as rear

I

is also the

bearing No

5

The difference is that an oil hole is

in the front bearing

d All upper and lower bearings

are

interchangeable Apply engine oil

4

surfaces

on

to main

both sides of

bearing

cylinder

block and cap and then install crank

one

j c6J

CONNECTINGROD the

is

shaft

PISTON AND

rods

type

same

5

1

3

No 2 and No 4

bearings inter

the same type Front bearing No

provided

Top ring is chromium plated on liner contacting face Second ring has larger taper surface than top ring In the combined oil ring upper rail same

No

bearing

are

Install piston rings

is the

Aembling cylinder head

Fig EM 83

center

Only

flanged type

Notes

b

cyl

inder block net

b All

InstalI top and second rings in right position with marked side up

a

Install baffle plate including

3

ignated de

en

3

86 EM

Fix

bearings

to 40 ft lb

Notes a

lalling pidon rings on

specified torque

Tightening torque 5 to 5 kg m 33 4

EM158

Fig

Install main bearing cap and tight bolts to

connecting rod

and connecting rod cap

Apply sealant to each side of rear main bearing cap and each comer of eylinder block as shown in Figure EM 79

b Arrange parts so arrow mark on bearing cap faces toward front of

engine Note

Clean back side of bearing

care

c

fully

STl3030001

tightening bearing

Prior

to

bolts

place bearing

position by shifting

cap

cap in proper crankshaft in

the axial direction d EM156

Fig

ENGINE ASSEMBLY

Installing piston pin

84 EM

is

The first step in engine assembly to bolt Attachment Engine

ST0526000 I

cylinder

to

hand ide

of

install block

on

right

block Next

Engine Stand ST0501S000 with engine bottom up

cap bolts gradually in two to three stages outwardly

Tighten bearing

from center bearing in the sequence 88 EM as shown in Figure e

After securing bearing cap bolts ascertain that aankshaft turns

smoothly

another 2

Set main

bearings at portion of cylinder block EM157

85 EM

Fig

Assembling piston and connecting rod

Notes a

Piston is

rod

with

tons

aid

pressed into connecting fitting force of 0 5 to 5 of

Piston

Pin

the proper

@

Rear

Front

III

D

III D

m It IlL D D D

i d

Press

Stand STl303000 I is necessary

pressing piston pin necting rod apply engine oil to pin and small end of connecting rod

When

into con

l

15

4 1

13

12

11 EM159

Fig EM 87 Main bearings

EM 22

j

1

@EM543

Fig EM 8S Torque sequence cap

0

bolt

Mechanical

Engine 6

Make

sure

proper end

that

crankshaft

has

Note

When

Crankshaft end

oil

seal

oil

engine

give mating

to

shaft to prevent scratches and fold ed lip Also give coating of oil to

play 18 0

0 05 to

installing

of

coating

play

mm

periphery of oil seal

0 0020 to 0 0071 in 9

Install

rear

end

plate

Install

10

flywheel securely tighten bolts to specified torque

and

Fig EM 94 Installing connecting rod cap

Tightening torque 14 to 16

101 II

kg

m

Note

to 116 ft lb

Insert pistons in corresponding

Install side oil seals into to

rear

as on

the

EM03470000

direction with respect to cylinders

same

side and

in

the

SlIme

13 Make sure that connecting rod big end has proper end play

EM03410000

bearing cap Prior

con

cylinder using Piston Ring Compressor

Fig EM 89 Checking crankshaft end play

7

Install connecting rods and

necting rod caps 80 that their signed numbers are positioned

I

main

installing apply

sealant to seals

EM544

Fig EM 92 Installing pi8ton rod Sembly a

Fig EM 95 Checking big end play Notes a

Apply engine

b Arrange 80 piston head

oil to

sliding parts notch

that

mark

faces to front of

Big end play on

gine c

Install other

piston rings

avoiding

thrust and Fig EM 90 Driving side oil seal

8

Install

rear

oil

seal

using

at

their

piston pin

Crank

1800

r Piston pin

in

3 mm 0

0 008 to 14

Ql2 0

in

Install cylinder head

assembly

the

directions

6

shaft Rear Oil Seal Drift STI5310000

to each

fit

0 2 to

en

Top ring

I iilring ireClioJ

Fig EM 96 Tightening

sequence

cylinder head

01

bolts

STl5310000 EM165

Fig EM 93 PUtan ring direction r

Thoroughly clean cylinder block

J

and head surface

12 EM163

Fig EM 91 Installing

rear

oi seal

Install connecting rod caps

Tightening torque 4 5 to 5 kg m 33 EM 23

Do not

apply

sealant to any other

part of cylinder block and to 40 ft lb

face

head sur

Engine Mechanical Turn crankshaft until No I

2 ton

TD C

at

is

pis compression

its

on

Make sure thai camshaft

3

Install chain slack side guide

aligned

are

groove

sprock

and plate oblong

notch

location

their

at

to

b Install Cront in

cylinder block

4

When

Adjust protrusion oC chain spindle to 0 mm 0 in

Note

ten

valves

are

Do not

separately

camshaft

or

0 0059 in

mm

d

Note that difCerent types oC bolts are used

e

Before

head

apart

front

installing

cylinder engine oil

crankshaft and

rotate

DifCerence must

upper Cace 15 0 be less than

from heads of pistons 5

diCCerence between

height

cover

sioner

correct

cylinder

installing that all

sure

gasket

cylinder block upper Cace and Cront

positions make

with head

cover

place

Check

c

Install chain tensioner

18

stroke

et

17

block 10

apply

on

cover

oC

coating

sealing lip

of oil seal

valves will hit

heads of pistons

Temporarily tighten

6

CD V

two

bolts

Fig re EM 96

sJiown in

Tightening torque 2

15 oil

kg

m

14 ft b

Install crankshaft sprocket and and fit oil pump drive gear

Fig EM 98 lmtalling chain tensioner

thrower

EMS11

Press new oil seal in front cover

19 lhat maling marks of crankshaft sprocket face 10 Cront

Note

Make

Notes

Install timing chain

cover

placed

Size M8

Make

sure

that crankshaft and

shaft keys point

cam

b BeCore

upwards

oil seal into Cront

pressing

give coating of engine oil

cover

periphery

of oil seal

This oil seal is

a

Do not

teristics

apply

grease to

Install

kg

7 2 to 9 4 ft lb

m

236 0

4 to 0 6 0 21

threaded seal type which has improved sealing charac

c

Size M6

to

in

315 0

10 to 13

sembled

Noles a

Tightening torque

oil seal should be reo when Cront cover is disas

Front

a

16

Fig

sure

EM lOD Front cover bolts

in

kg m

2 9 to 4 3 ft lb

crankshaft

and

pulley

water pump assembly then set No I piston at ToO C on its compression

stloke

sealing lip Crankshaft pulley Install front

20 Fuel

pump drive

earn

2

Chain guide

3

Chain tensioner

4 5

Crank sprocket earn sprocket

6

Chai

cover

with

gasket in

nuI

tightening torque 12 to 16 kg m B7

place

to 116 ft lb

guide EM439

b Set

timing chain by

OOgning

its

marks with those oC crank

mating shaft sprocket and camshaft sprock et at the right hand side There are forty four chain links between

mating c

NO

is

Cactory

EM546 EM545

Fig EM 99 Installing fronl

Fig EM Ol

lnstallingcran

haft

pulley

COlHlr

water

adjust

camshaft

sprocket

22

adjusted

chain stretches excessively at No 3

hole set

of

timing

location hole numbers

marks and

Finally

the Notes a

a

mark mark

two

When

d Use

Timing Timing

and

pump

marks of timing chain hole

2

1 2

according sealant to Cront

Apply corners

block

as

cover

and

oC upper section of cylinder shown in

Figure EM

EM 24

78

tighten head bolts

specified torque to the

in

to

three steps

lightening

sequence

shown in Figure EM 96 Note thai Iwo types of bolts used

are

Engine Mechanical Speci Wren

Tightening torque

ol Cylinder Head Bolt

h 8110120000

Oil strainer bolts 0 8 to I l

Tightening torque 1st turn 4 0 kg

2nd turn 6 0 kg

m

29 ft lb

m

43 ft lb

kg

I

m

47 to 61 ft lb

O

a

Apply at four

b

26

A

Figure

80 EM

Oil

should be

pan

pattern

O

R

O

m

valve

tigh tened

to a final

in

torque

4 3 to 6 5 ft lb

clearance

to

the

dimensions

Special tool Pivot Adj iier STl064000l

A

EM

Tightening torque 5 0 to 6 0 kg m 36 to 43

ft lb

176

Fig EM I02 Cylinder head boll

EM I04

Fig

24

Install

11l6lalling oil pump

fuel pump

water inlet

elbow and front engine slinger in their

Notes

tighten

Be sure to

two small bolts

positions

operated for retighten if neces

b After engine has been several minutes

Fuel pump tightening torque 12 to 1 8

sary

kg

m

8 7 to 13 0 ft lb

Install oil pump and distr butor

23

5 ft lb 6

B

A

a

Adjust

specified

B

3 to 4

sealant to the step portions mating surfaces as shown in

of 0 6 to 0 9 kg

A

O

B

5 8 to 8 0 ft lb

Notes

cross criss

B

m

0 6 to 0 9 kg m

3rd turn 6 5 to 8 5

kg

Oil pan bolts

driving spindle

Note

in front cover

pump spacer and spacer and block

Tightening torque 1 to 1 5

kg

to

forget

Do not

install fuel

packing

spacer and fuel

pump

m

8 0 to 10 8 ft lb

Fig EM I05 Adjusting valve clearance

between b After engine has been assembled run it for at least several minutes

Install oil strainer oil pan gasket

25

and

and oil pan

to the

finally adjust clearance specifications

warm

Notes a

Assemble oil pump and drive spin die aligning driving spindle face with oil pump hole

b Install oil pump together with drive spindle so that the projection on its

top is located

position shape bow

at the

II 25

will

front c

Do not

forget

a m

point the smaller be facing toward the

At this

to install gas

27

Install rocker

cover

to

cylinder

Note et

Make

that

sure

rocker

cover

others

It

bolts is

of the

one

longer

than the

IC D F

secures

assist

Install

intake

Install

face which

manifold

air

pump

cooler compressor to EM

25

bracket and

cylinder

block

to

ex

The intake manifold

comes

into contact

with

with that of

gasket should be

even

exhaust manifold

Note that two dif

ferent sizes of attaching bolts

bracket 28

29

haust manifold

head

Tightening torque 2 5 kg m 18 0 ft lb

are

used

Engine Mechanical Install heatshieid plate

30

mani

on

fold assembly

gallery pipe

air

on

ex

pot bracket and

dash

intake manifold

dash pot 46 Connect all air

vacuum

hoses and then secure with

haust manifold

manifold

Install

32

Install to

Install

31

45

manifold assembly

gasket and cylinder head

on

I

valve

hose A B valve to E G R passage vac

uum

hose

A B

3

8 7 to 116 ft lb

clamps

block to P C V

Cylinder

2

Tightening torque 1 2to 1 6kgm

and fuel

valve

to

passage air

E G R

I

hose Install blow by gas pipe on cyl inder block and tighten with rear 33

engine slinger 34 ket

uum

thermostat

housing

housing gas and thermo

6

35

Install thermal

apply

a

vacuum

Before

thermostat

valve

on

installing

housing liquid packing slightly

to the

threads on

cylin

Install

and

EGR

E G R valve

on

passage intake manifold

tube and exhaust manifold Install check valve

39

air

gallery on

Install air control valve

on

air

cleaner bracket California models Install

combined 43

vacuum on

and fuel

cylinder

tubes

Check valve to air control valve

10

Install

seat

plate

heatshield

joint

Carbure10r tightening torque 5 to 1 0 kg m 3 6 to 7 2 ft lb 0 When

sure

to

vacuum

valve to

hose

vacuum

Thermal

I

47

valve

to

Install carburetor air cleaner

on

vacuum

vacuum

hoses

as

2

follows to

instalUng joint

to

exhaust manifold

seat

be

Air cleaner to rocker

Air cleaner to air control

cover

hose valve

Air cleaner toA B valve hose

6

Other

put the duct into primary

hole in intake manifold

vacuum

er

51

fasten it to

cylinder block by hand Note

Do not overtighten

55

flit or oil

occur

Install alternator bracket alternator

cooling

adjust

fan

and

belt

5

50

bracket oil filter oil pressure switch level gauge and water drain plug

ing bar

air pump hose

4

hoist and

overhead

lifting cable hoist engine away from engine stand and then down onto engine carrier 54 Install right engine mounting

leakage may

Air c1eaner

hoses

56

Adjust the deflection of drive

belts when thumb pressure is applied midway between pulleys A pressed force is above 10 kg 22 0 lb Deflection ofdrive belts

Install spark plugs in place Connect all distributor high ten

sion cables to

an

When installing oil filter

3

49

Using

oil

tube hose

Air cleaner

I

48

and carburetor

Note

Thermal

hose

head

Install distributor assembly

44

hose

hot air duct

intake manifold

42

53

9

vacuum

carburetor and then connect air and

on

Install air cleaner bracket

41

hose

Air control valve

pipe 40

vacuum

8

vacuum

Connect E G R tube to E G R

38

spark delay valve

I

embly

Fig EM I07 In talling clutch

Fuel tube to fuel pump fuelhose Distributor to vacuum switch or

E G R valve

der head 37

fuel

carburetor to

hose

Install FJ C D bracket

36

KV30100200 EM440

ube

hose

7

stat

vac

hoses Fuel

5

Install thermostat

I

Vacuum tube to carburetor

4

8 to 12 315 0

mm

to

472 0

in

spark plugs

Install air pump drive belt cool compressor and idler

Install

left

pulley

engine

mounting

bracket

S

52

Install

flywheel

with

clutch Clutch

assembly

on

Aligning

Bar

KV30100200

Tightening

torque 2 to 2 2 kg 1

m

8 7 to 15 9 ft lb

EM613 J

2

Heatshield plate Primary hole

3

Duct

Fig EM lOB Fan belt tension

4

Joint seat

5

Secondary hole EM534

57

Fig EM I06 Installing carburetor joint seat

level

EM 26

Fill

engine oil

up to

specified

Engine Mechanical


GENERAL SPECIFICATIONS L20B

Engine model

4 in line

Cylinder arrangement co

Displacemen t

cc

Bore and stroke

mm

85

in

x

86

19 1 3 35

x

3 39

O HC

Valve arrangement

I

Firing order Engine idle

J

1 952

in

42 3

rpm

750

Manual transmission Automatic transmission

in

D

650

range

8 5

ratio

Compression

Oil pressure Warm at 2 000 rpm 3 5 to 4 0

kg cm2 psi

50 to 57

SPECIFICATIONS a

Valve mechanism Valve clearance

Warm

mm

in

0 25 0 010

Intake

Valve clearance

mmOn

Cold

Intake

0 20 0 008

Exhaust

0 25 0 010

Valve head diameter

Valve

0 012

30 0

Exhaust

mm

in

Intake

42 0 to 42 2

1 654 to 1 661

Exhaust

35 0 to 35 2

1 378 to 1 386

stem

diameter

mm

in

Intake

7 965 to 7 980

3136 0

to

3142 0

Exhaust

7 945 to 7 960

3128 0

to

3134 0

115 2

524 4

to

4 535

555 4

to

4 567

mmOn

Valve length Intake

114 9

Exhaust

115 7 to 116 0

mmOn

Valve lift

5 10

Intake and exhaust

Valve spring

to

out

of square

Valve spring free length Intake and exhaust

mm

in

mm

in

413 0

less than 1 6 0 063

Outer

49 98

1968

Inner

44 85

J 766

EM 27

Engine Mechanical pressured length

Valve spring

kg in lb

mm

valve open Intake and exhaust

IM 5 49 0 1 29 108 24 5 25 5 0 965 56 2

Outer Inner Valve

spring assembled height

valve close

kg

mm

lb in

Intake and exhaust 40 0

Inner

35 0 12 3

Valve guide length Intake and exhaust Valve guide Valve

guide

height from

mm

head surface

inner diameter

in

mIll

in

mm

in

service

outer

59 0

323 2

10 6

417 0

8 000 to 8 018

Intake and exhaust Valve guide

3 1575 47 0 21 27 I 378 1

Outer

0 3150 to

3157 0

diameter mm

parts

in 12 223 to 12 234

Intake and exhaust

4812 0

Valve guide to stem clearance

mm

to

4817 0

in

Intake

0020 to 0 053 0 0008 to 0 0021

Exhaust

0 040 to 0 073 00016 to 0 0029

in mm

Valve seat width Intake

14 to 16 0 0551 to 0 0630

Exhaust

1 8 to 2 2 0 0709 to 0 0866

Valve seat angle 450

Intake and exhaust Valve seat interference fit

mm

in

0 113 0 0032 to 0 0044

Intake

0 081

Exhaust

0 064 to 0 096 0 0025 to 0 0038

Valve guide interference fit

b Camshaft and Camshaft end

timing

to

mm

in

0 027 to 0 049 0 0011 to 0 0019

rnm

in

0 08 to 038

rnm

in

chain

play

Camshaft lobeift

00032 to 00150

7 0 0 276

Intake and exhaust Camshaft joumal diameter

mm

in

47 949 to 47 962

1st 2nd 3rd and 4th

1 8877 to 1 8883

Camshaft bend Camshaft journal to

mm

bearing

clearance

Camshaft bearing inner diameter

0 02 0 0008

in

mm

in

rnm

in

Q38 to 0 067 0 00 I 5 to 00026 0

48 000 to 48 016

1st 2nd 3rd and 4th

1 8898 to 18904

EM 28

Engine c

Connecting rod Center distance

mm

in

146 5 748

mm

in

1493 to 1 506 00588

Big end play

mm

in

0 20 to

Connecting rod bearing clearance

mm

in

Bearing

thickness Standard

Connecting

d

rod bend

or

torsion

30 0

to

00593

0 008 to 0 012

D25 to 0 055 0 0010 to 0 0022 0

per 100 mm or 2 937 in mm

in

Journal diameter

mm

in

Journal taper

mm

in

less than 0 03 0 0012

Crankshaft and main bearing

out ofround

Crankshaft free end play Wear limit of dittoed play

Crank pin taper

942 to 59 955

59

3 0

in mm

out of round

Main

bearing

thickness StJlndard

Main

bearing

clearance

0118

0

49 961 to 49 974

in

mm

in mm

1 827 to 1 835

in

Wear limit of dittoed clearance

mm

in

0 12

0 0047

Crankshaft bend

mm

in

0 05

0 0020

in

less than 0 15

1 9670 to 19675

0 0004

less than 0 01

mm

Flywheel

3604 2

0 05 to 0 18 0 0020 to 0 0071

in

mm

io

3599 2

less than 0 0 I 0 0004

in mm

Crank pin diameter

0 020 to 0 062

0 0719

to

0 0722

0 0008 to 0 0024

runout at clutch disc contact face mm

e

Mechanical

0 0059

Piston Pistondiarneter Service standard

in mm

84 985

85 035

to

3 3459 to

0 50 0 0197

Oversize

in mm

85 465 to 3648 3

100 0 0394

Oversize

mm

in

mm

in

3478 3 515 85

to

3667 3

85 965 to 86 015 3 3844 to 3 3864

Ring

groove width

Top

2 030 to 2 050 00799 to 0 0807

Second

2 020 to 2 040

00795

Oil

4015 to 4 040

0 1581 to 0 1591

Piston to bore clearance

mm

in

Piston pin hole

mm

in

0 95 to 1 05

mm

in

21001

to

21008

mm

in

20 993

to

20 998

Piston

f Piston

set off

pin hole diameter

Q25 to 0 045 0 0010 0

to

to

0 0803

0 0018

0 0374 to 0 0413

0 8268 to 0 8271

pin

Pin diameter

0 8265 to 0 8267 Pin

length

in mm

72 25 to 73 00 2 8445 to 2 8740

Piston pin to piston clearance

mm

in

Interference fit of piston pin to connecting rod mm

0008 to om 0 0 0003 to 0 0004

bushing

in

om 5 to

EM 29

035 0

0 0006 to 0 00I 4

Engine Mechanical g

Piston

ring

Ring height Top and second

mm

Side clearance

mrn

Ring

in 1977 to 1 990 0 0778 to 0 0783 in

Top

0 040 to 0 073 0 0016

Second

0 030 to 0 070 0 0012 to 0 0028

0 0029

in

mm

gap

to

040 0 0098

0 0157

Top

0 25

Second

0 30 to 0 50 0 0118 to 0 0197

30 0

Oil

to

to

to 0 90 0 0118 to 0 0354

h Cylinder block

Cylinder bore

85 000 to 85 050

in mm

inner diameter

3 3465 to

Wear limit of dittoed inner diameter

Cylinder bore taper and Difference in cylind

out of round

bore

Surface flatness i

3484 3

mm

in

0 2 0 0079

mm

in

om 5 0 0006

mm

in

0 05 0 0020

mm

in

less than 0 05 0 0020

Cylinder head Surface flatness

less than 0 05 00020

in mm

TIGHTENING TORQUE head bolts

kg

m

fl lb

5 to 6

kg

m

ft Ib

5 to 5 5 4

kg

m

ft Ib

bearing cap bolts

kg

m

ft lb

Camshaft bracket bolts

kg

m

ft lb

1 8 to 2 0

Camshaft sprocket bolt

kg

m

ft lb

12 to 16

Oil pan bolts

kg

m

ft 1b

0 6 to 0 9

3 to 6 5 4

Oil pump bolts

kg

m

ft lb

J to 1 5 I

8 0 to 10 8

Oil strainer bolts

kg

m

ft lb

0 8 to 1

5 8 to 8 0

Oil pan drain

kg

m

ft lb

2 0 to 3 0 14 to 22

Rocker pivot lock nuts

kg

m

ft Ib

5 0 to 6 0

Camshaft locating plate bolts

kg

m

ft lb

0 6 to 0 9

Carburetor

kg

m

ft lb

5 to 1 0 3 6 to 7 2 0

Cylinder

Connecting rod big end

nuts

Flywheel fixing bolts Main

plug

nuts

5 8

14 to 16

5 4

to

47 to 61 33

101

to

40

to 116

5 33 to 40

13 to

15

87 to 116

36

to

3 4

to

43 5 6

Manifold bolts

kg m

ft lb

2 to 16 8 7 to 116 1

Fuel pump nuts

kg m

ft lb

1 2 to 18 8 7 to 13 0

Crank pulley bolt

kg m ft lb

Water pump bolts

kg

m

ft Ib

Front

kg

m

ft lb

cover

bolts

12 to 16 87 to 116 4 0 8

mm

315 0

in dia

6 mm 0 236 in dia EM 30

to

05

2 9 to 3 6

1 0 to 1 3 7 2 to 9 4 4 to 0 6 2 9 to 0

3 4

Mechanical

Engine

TROUBLE DIAGNOSES AND CORRECTIONS Probable

Condition I

Corrective action

cause

Noisy engine

Knocking of crankshaft and bearing

Seized bearing

Replace

Bent crankshaft

Repair or replace

Uneven

Knocking of piston and connecting rod

Replace

bearing

Loose main

wear

Correct

of journal

Replace

Loose bearing

Replace

Seized bearing

Replace

Loose piston pin

Replace pin

Loose

in

piston

Improper connecting Loose

rod

Realign

alignment

Replace

Replace bearing

Excessive axial play

Broken

Timing chain

noise

gear teeth

Repair

gear

Replace

eam

Worn and

Worn

or

damaged

Replace

chain

Replace

sprocket and

Worn

thrust plate

Adjust

chain tension

Improper

bushing

Replace

bearing

Rough

or

bearing

Recondition cylinder

cylinder

Broken piston ring

Camshaft knocking

cen ter

Excessive crankshaft end play

tension

broken

or

adjusting

Replace

mechanism Excessive camshaft and

bearing clearance

Camshaft and valve

Improper valve clearance

mechanism knocking

Worn

adjusting

Adjust Replace

screw

Replace

Worn rocker face Loose valve stem

Water pump

II

knocking

Replace

Replace guide

1 guide i1

Weakened valve spring

Replace

Seized valve

Repair or replace

Improper shaft end play

Replace

Broken

impeller

Replace

Improper valve clearance

Adjust

Insufficient clearance between valve stem

Clean stem

Other mechanical troubles

Stuck valve

and

or ream

guide

Weakened

Biting

or

or

broken valve spring

damage of valve stem

Replace Replace Use

Poor Quality of fuel

EM 31

or

clean

ood fuel

guide

Engine Mechanical Condition Seized valve

Excessively

seat

worn

cylinder and piston

Probable

Improper

Corrective action

cause

valve clearance

Adjust

Weakened valve spring

Replace

Thin valve head edge

Replace

Narrow valve seat

Reface

Overheating

Repair

Over

Drive at proper speeds

speeding

valve

or

Stuck valve guide

Repair

Shortage of engine oil

Add

Dirty engine oil

Clean

or

replace

replace oil

crankcase

replace oil and

element Poor quality ofoiL

Use right oil

Overheating

Repair

or

replace

Repair

or

replace

Wrong assembly

of piston with connecting

rod

Improper piston ring

clearance

Adjust

Broken piston ring

Dirty

Faulty connecting rod

Replace

aii cleaner

Clean

Mixture too rich

Adjust

Engine

Drive at proper speeds

over

run

Stuck choke valve

Clean and

Overchoking

Start correct way

Shortage

Add oiL

of engine oil

Low oil pressure

Correct

Poor quality of engine oil

Use proper oil

Rough surface of craokshaft

Grind and replace

Clogged

Clean

Bearing

oil passage worn or

eccentric

Bearingimproperly

Replace

assembled

Correct

Loose bearing

Connecting Faulty crankshaft bearing

adjust

Shortage

of

rod

Replace

alignment

incorrect

engine oil

Repair Add

Low oil pressure

or

or

replace

replace

Correct

Poor quality of engine oil Craokshaft journal

worn or

Use proper oil of out

Clogged

oil passage in crankshaft

Bearing

worn or

eccentric

Bearing improperly

or

Repair Clean

Replace

assembled

Eccentric craokshaft

round

Correct

bearing

Replace

32 EM

bearing

oil

niter

IFfIDrnJrnJ

1r DfA 1r ijJJlk1 3u

AT

WHIPPL E 480 VETERANS

u Sa

e

TEL EPHONE 3155 6390

VETERANS

BL V

PlfIDrnJ1r 1 e S

REDWOOD CITY

D

CALIFORNIA

I

DATE

NAME

ORDER

CU5T

DDR E55

OUAN

94063

CHARGE

I

PART

WHOLESAl E

RETAIL

rETe rDS I

NO

I

NO

J LIST

DESCRIPTION

NET

I

r

1

fr r

k

AI

v

1

I w

idP

Ji i

II I J

I

1 ll

HI

tl

1

1

I

11 s vnAAwf

11

Q

C r

Y J

h

If

Ii

JJ

plt

is

NO

REFUND AFTER 30 DAYS

NO

REFUND ON

10

TAX

ELECTRICAL OR

RESTOCKING

CHARGE ON NO

CARBURETOR

PARTS

REFUNDED MER

HANDISE

REFUND

WITHOUT THIS

INVOICE

REC

O

BY

r

Engine Mechanical

SPECIAL SERVICE TOOL

Tool number

Description

No tool

ST050lS000 stand

Engine

Unit

name

mm

in

This engine stand assembly is used for disassembling or assembling engine block or differential carrier throughout

For

Reference

use

page

on

Figure No

All

Fig

or

EM II

models

3600 in all directions

assembly ST050 11000

Engine

stand

ST050 12000

Base

SE184

2

ST0526oo0l

This engine attachment is installed to engine stand ST0501S000 in disassembling

or

Ll6

Fig

EM

II

Fig

EM 18

Fig

EM 105

Ll8

assembling engine

Engine attachment

L20B

Q

li SE185

3

STl 0120000

Special in

series L

hollow set bolts

engines

head bolts and its head

1 rench

wrench

4

STl 064000 I Pivot

can

cylinder heads torque cylinder

used in tightening

This wrench is used to

Cylinder head bolt

10

are

All L series

be inserted into the torque

0 39

SE186

This tool is used

togetller with

tightening pivot

lock nut for valve clearance

a

torque wrench

in

adjustment

series L

adjuster

SE187

33 EM

Al

Engine Mechanical

For

Tool number

Description

No

tool

S

Unit

name

mm

in

t Referenl

use

page

or

on

Figure No

KV10 1039S0 Valve

guide

reamer

set

This o 0

STIlO81000

0

guide

All

is used for

Pressing used guide out of place Driving a new guide into place

Finishing

the bore of new

Fig

44 EM

Fig

4S EM

Lseries and A series

guide

Reamer

12

2 mm dia

STlI 032000 Reamer

8 0

mm

dia

STl1320000 Drift

V SE192

6

STll6S0001 Valve seat cutter set

This valve seat cutter set is used

to

or

refinish

a

valve seat

All L series

SE193

7

STl2070000 Valve lifter

ol is used to compress valve spring by the combined action of its eam and lever thereby facilitating the removal

This

or

t

installation of valve collet for general

use

SE194

34 EM

All

Fig

models

Fig

EM 32 8l EM

Engine Mechanical

Tool number

Description

No tool

8

name

Unit

This tool is used with

ST13030001

a

press to drive

pin into

or

mm

in

out of

For

Reference

use

page

on

Figure No

All L series

connecting rod

or

Fig EM 29 Fig EM 84

Piston pin press stand

1

20 0 79 I

8 M

e

120 4

0 722 SE1BS

9

engine into Crankshaft

push a lip type rear oil seal for place by giving hammer blows

This tool is used to

ST153 10000 rear oil

Lseries

All

Fig

EM 9l

Fig

EM 25

series L

seal drift

SE189

10

KVI01041S0


remove

Crankshaft main

bearing

cap

in main

All

the cap from main bearing

When using thds tool turn its

adapter

into the threaded hole

Lseries

bearing cap

puller

KVI0104110

Body 250

9 8

l

ST165 12001

Adapter

se1g0

II

ST166 10001


pull pilot bushing

out of

All

place

L series Pilot

bushing puller

SE191

35 EM

Fig

66 EM

r

Engine Mechanical

Tool number

Description

No tool

12

name

Unit

mm

in

This tool is used to prevent chains from falling out of place in removing cylinder heads or earn gears and shafts

STl742000l Chain stopper

40

For

Reference

use

page

on

Figure No

All

or

Fig EM

19

series L

S1 1

r SE196

13

STl9320oo0 Oil filter wrench

This tool is used

to

the filter do not

use

take oil filter out of place this tool to prevent

n

excess

tightening

tightening

All

Page EM4

models

120 4 7

SE197

14

KV30100200

This tool is used to install clutch

assembly

to

All

engine

Fig EM 107

Lseries Clutch

aligning

bar

SEGOl

15

EM03470000

This tool is used to compress piston rings while piston is being inserted into cylinder

Piston ring compressor

2

SE199

36 EM

All models

Fig EM 92

SECTION EL


I NISSANJ NISSAN MOTOR CO TOKYO

LTD JAPAN

ENGINE LUBRICATION SYSTEM


EL

2


EL

5


EL

5


EL

6


ENGINE LUBRICATION SYSTEM CONTENTS LUBRICATION

CIRCUIT

EL 2

Inspection

EL 3

01 L PUMP

EL 2

OIL PRESSURE

Removal

EL 2

OIL FILTER

EL 4

Installation

EL 2

RELIEF

EL 4

Disassembly

and assembly

REGULATOR

EL 4

VALVE

VALVE

EL 3

From

directly through

this

cam

to

holes

camshaft

go

bearings

brackets

Oil supplied No

oil

gallery all

to

through the No 2 bearings is then

and

3 camshaft the

lobe

rocker arm

valve and

the oil

through

gallery

fed eam

in the

camshaft and the small channel at the base circle portion of each

earn

OIL PUMP The oil pump is secured on the bottom of the front cover with four bolts and driven by the oil pump drive spindle assembly which is driven by the helical gear

an E L049

Fig

ElrI

Lubricating

outer and inn

circuit

on

the crankshaft

The oil pump assembly consists of oil pressure regulator valve and r

rotors

The spring loaded oil pressure regu lator valve limits the oil pressure to

LUBRICATION CIRCUIT The

pressure is

engine

maximum of 5 6

lubrication of the

accomplished

by

tro

a

choid type oil pump This pump draws the oil through the oil strainer into pump

housing

cylinder head

to

and then forces it

the full flow type oil filter into the main oil gallery Part of the is

supplied

all

Removal I

Remove distributor

2

Drain engine oil if necessary Remove oil pump body with

3

crankshaft

drive spindle

assembly

chain

bearings chain

to

kg

provide lubrication

of the valve mechanism and timing chain as shown in Figure EL2

through

oil

a

80 psi

em

tensioner and timing supplied to crankshaft

Oil

is fed to connecting rod bearings through the drilled passages

bearings

in the crankshaft

jet

holes

on

Oil

injected

cates

the

cylinder walls

pins

The

other part

brought

to

from

Installation

connecting rods Iubri

the

oil

and piston

of the oil

gallery

in

I

is

ELOSO

the

Fig

EL 2

Lubricating EL 2

vallie mechanism

Before

engine piston

installing

oil

pump

turn crankshaft so that No is at TD C

on

I

ENGINE LUBRICATION SYSTEM 2 oil

housing with engine then align punch mark of spindle Fill

pump

with hole

Figure

in oil

pump

as

shown in

wear

Disassembly and assembly I

EL 3

Remove

bolts

pump

attaching

cover

and

cover

pump

3

cover

and slide out pump rotors 2 Remove regulator cap

gasket

Install

and related parts 4 Install outer

Punch mark

valve

regulator

pressure

rotor

inner

inner

shaft

rotor

for

wear

scoring

or

5

regulator

valve and spring 3

Check

looseness in pump body 4 Inspect regulator valve for

Check

regulator spring

to

see

that

it is not worn on its side or

collapsed

6

check tip

Using

feeler gauge

a

clearance

2

and outer rotor to

clearance

I

shown in Figure EL 7

body

rotor

and shaft in pump body and do not

gasket

turn cover

up

CD

EL009

EL3

Fig

3

Using

a

Aligning punch mark and oil hole

new

install oil

gasket

pump and drive spindle assembly that the projection on its top

so

located in II

at

this time

25

a

m

position

the smaller bow shape will

be placed toward the front in

Figure EL

4

9@ @

J i

It

L

I

tr

Regulator spring

7

Washer

8

4

Outer rotor Oil pump cover

Regulator cap Cover gasket

5

Regulator

3

9

Fig EL 6

Oil pump

I

pindle

3

Tip clearance Gap between

rotor and

straight edge

4

Gap

body

and

straight edg e

rotor

between

Fig EL

7

7

Place

body clearance

Checking

a

rotor clearance

straight edge

Wash all

parts in cleaning solvent

and dry with

compressed ir Inspect pump body and

for cracks 2

EL011

Ascertain

Imtalling oil pump

whether

gagement is in order

top of

spindle

or

not

the

by checking

or

Inspect

cover

excessive wear

0 0012

to

rotor side clearance cover

pump rotors for excessive

clearance

0 0024

rotor to

Olm

in

Rotor tip clearance

@

mOl

in

mm

inl

then

with gasket should

satisfy the specifications

0 04 to 0 08 0 0016 to 0 0032

bottom cover

in

rotor to bottom

Wear limit

Less than

0 12

0 0047

020 0 0079

0 20 0 0079

through distributor fit

ting hole 4 Tighten bolts securing oil to front cover

Rotor side clearance

en

the

Outer pump

the

0 03 to 0 06

The gap should be mm

Standard

Fig EL 5

across

between body and straight edge or gap 3 between rotor and straight edge

Inspection I

o

Outer

face of pump and depress it slightly as shown in Figure EL 7 Check gap 4

EL010

Setting drive

to

1 2

valve

d

I

EL 4

CD@

6

2

J V

r @

Oil pump body Inner rotor and shaft

1

c

Fig

@

shown

as

JI

Front

El012

is

rotor to

clearance

body

D EL 3

0 15 to 0 21

0 0059 to 0 0083

0 5

0 0197

ENGINE LUBRI CATION SYSTEM Note

Pump

rotors and

body

are

separately If pump body are damaged or

not

serviced

rotors

or

worn

replacement of the entire oil pump assembly is necessary

OIL PRESSURE REGULATOR VALVE oil pressure regulator valve is the released At adjustable

The not

position the valve permits the oil to by pass through the passage in the cover

pump

the inlet side of the

to

pump Check regulator valve spring to ensure that spring tension is correct

Tightening

EL014

Fig ELB Regulator value

torque

kg

m

ft Ib

l to 15

bolts

kg

m

ft lb

07

cap nut

kg

m

ft lb

4 to 5

Oil pump mounting bolts Oil pump

cover

Regulator valve

to

8 0 to 11

10 5 Ito 7 2 29 to 36

Specifications Oil pressure at

Regulator

kg cm2 psi

idling

mm

in

525

2 067

Pressured length

mm

in

34 8

370 1

valve opening pressure

oil

filter is

a

cartridge type

filter element should be

placed periodically

reo

with the use of Oil

Filter Wrench ST19320000 When installing it to

kg

em2

35 to 5 0 50 to 71

psi

RELIEF VALVE

OIL FILTER The

an

oil filter fasten

The

relief

valve

With

located

at

the

portion securing oil fIlter to the cylinder block by passes the oil into the main gallery when the oil fIlter element is excessively clogged

Do

not

leakage may

overtighten

filter

or

oil

fIlter

removed

check

operation Inspect for a If replace or broken valve necessary remove valve by

valve unit for cracked

center

cylinder block by hand

Note

to 40

valve spring

Regulator

oil

II

length

Free

The

0 8 to 2 8

ment

is

prying

it

Install

a

tapping

it

out

with

new

valve

a

screwdriver

in

place

by

oil

occur

STl9320000

EL016 EL015

Fig EL 9 Removing oil filter

4 EL

Fig

EL JO

Relief lJOlue


SERVICE DATA AND SPECIFICATIONS Oil pump Wear limit

Standard

rotor to bottom cover Rotor

tip clearance

Outer rotor to body clearance

Oil pressure

regulator

mm

in

mm

in

mm

in

0 0079

0 0016 to 0 0032

less than 0 12

0 20 00079

0 0047

05

0 15 toO 21

0 0197

0 0059 to 0 0083

valve

kg cm2

Oil pressure at idling

0 8 to 2 8

psi

II

to 40

valve spring

Regulator Free

0 20

0 04 to 0 08

Rotor side clearance

Pressured

in

52 5

2 067

mmOn

34 8

1370

mm

length length

5 to 5 0 50 to 71 3

kg em2 psi

Regulator valve opening pressure Tightening torque

Oil pump

cover

bolt

Regulator

valve cap nut

5 8 0 to 10 8 1

1 to

m

ft lb

kg m

ft lb

0 7 to 1 0 5 1 to 7 2

kg

ft Ib

4 to 5

kg

Oil pump bolt

m

29 to 36


Condition

Oil leakage

Damaged

or

Corrective actions

causes

cracked body

Replace

cover

Oil leakage from gasket

Replace

Oil leakage from regulator valve

Tighten

Oil

leakage

from blind

Leak of oil in engine oil pan

Correct

pressure

Dirty oil strainer

Clean

or worn

quality engine

or

replace

Replace

pump rotors

Replace

Faulty regulator Use of poor

replace

Replace

plug

Decreased oil

Damaged

or

Replace

oiL

Warning light

Decreased oil pressure


remains

Oil pressure switch unserviceable

Replace

Electrical fault

Check circuit

Excessive backlash in pump rotors

Replace

on

engine running

Noise

EL

5



Tool number No

Description tool

name

STl9320000

Unit

This tool is used to take oil f1Iter out of place the f1Iter do not

Oil filter wrench

I

use

this tool to prevent

nun

in

Reference

use

page

on

Figure No

In tightening

All

tightening

models

excess

120 4 7

SE197

6 EL

For

Fig

or

EL 9

SECTION CO

COOLING SYSTEM


COOLING SYSTEM SERVICE DATA AND

SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS

LNISSAN I NISSAN MOTOR CO TOKYO

LTD JAPAN

CO 2 CO 6 CO 7

Cooling System COOLING SYSTEM CONTENTS DESCRIPTION COOLANT

LEVEL

DRAINING

INSPECTION

4 CO 4 CO

TEM COUPLlNG

CO 2

PUMP

REMOVAL

OISASSEMBL Y

CO 2

AND FLUSHING THE

COOLING SYSTEM WATER

CO 2

INSPECTION

CO 2

AND INSTALLATION

CO 5

REMOVAL

DISASSEMBLY

CO 3

INSPECTION

INSPECTION AND ADJUSTMENT

CO 3

AND INSTALLATION

CO 5 CO 5

RADIATOR

CO 3

REMOVAL AND INSTALLATION

CO 5

THERMOSTAT

CO 3

TORQUE COUPLING

4 CO

4 CO

CO 5


CO 5

INSPECTION

CO 6

DESCRIPTION The cooling system is of the con ventional pressure type A centrifugal pump installed on the timing chain cover

serves

to circulate

the coolant

The pressure type radiator filler cap installed on the radiator operates the

cooling system at higher than atmos pheric pressure The higher pressure raises the boiling point of the coolant and in

creases

the

cooling efficiency

of the

If it is necessary to remove radiator cap wben radiator is hot turn cap

radiator When the thermostat is closed the

counterclockwise to the r

slowly

coolant remains in the cylinder head and block for swift warming up of the

step After all pressure in the cool ing system is released tom cap passing the stop and remove it

engine After it reaches normal oper ating temperature the coolant circu lates

through the radiator cooling fan drive coupling type The

is

of

a

DRAINING AND FLUSHING THE

COOLING SYSTEM

To drain the

cooling system

re

radiator cap release drain cock at the bottom of radiator and drain move

plug

on

the

right side of cylinder

block If the heater system is installed set heater temperature control valve to open position After the coolant is drained completely close drain cock and plug and refill the system with clean soft water

C0055

Fig CO I Cooling ry lem

PUMP

The water pump

COOLANT LEVEL

Caution

The coolant level should be check ed and maintained at SO

WATER

mm

197 in

below the upper face of filler neck when the engine is cold

To

injury quickly

avoid

never

serious

remove

when

personal

I3diator cap

engine is hot Sudden release of cooling system pressure is very dangerous CO 2

and

torque

cooling fan pulley coupling are a unitized

construction

The water pump is of

type which is mounted front

cover

a

centrifugal

on

the engine

Cooling System The pump shaft is supported by a row of ball bearings press fit in

Adjustment

Tightening torque

double

4 to 0 5 0

aluminum die cast pump body The bearings are permanently lubricated

3 0 to 3 6 ft lb

an

and sealed to prevent loss oflubricant and entry of dirt The

pump is provided with an impeller which turns on a steel shaft The steel shaft

rotates

together with

the torque coupling wheeL The volute chamber is built in the engine front cover

The inlet of the pump is connected to the radiator s lower tank

by

Fan

justed

leaks at pump 3

and

Install fan blade

tighten

at

taching bolts securely Install belt and

adjust for specified tension 4 Operate the engine at

fast idling

and recheck for leaks

belt should be at all times

belt

ad

causes

of alternator and water pump bearings A loose belt brings about

improper cooling fan and alternator operation

water pump

Check the belt slack between alter nator and fan

pulley by force of 10 kg

22 lb

Slackness of fan belt 8 to 12

Ensure that clearance between

shroud and Can is

properly

tight

A

wear

Install fan shrouds

Note

hose

a

m

Fill cooling system and check for

2

5

assembly

kg

even

at any

mm

47 in 0

0 31 to

place If adjustment is necessary loosen retaining alternator adjusting bar

bolt

to alternator Move alternator toward

DISASSEMBLY Water pump is made of aluminum and its bearing outer race is of a press fit

type

For

this reason

or

away from

engine until

the correct

tension is obtained

water pump

should not be disassembled

TORQUE COUPLING

i o

INSPECTION AND

Except air

CQ047

Fig CO 2 Water pump and engine front

ADJUSTMENT


Inspection

models

Inspect pump assembly for the fol lowing conditions and replace if nee

The torque coupling keeps the fan speed at 2 500 rpm rated or below to

essary

a

clean

1

Badly rusted or corroded body sembly and vane

2

Excessive end play

con

bearings

in

or

as

roughness of

operation

assembly

Oil leakage in torque

speed a

It also

helps

coupling

at

high engine

reduce fan noise to

during high speed opera

minimum

tion

This unit is

3 Reduced cooling efficiency due to deteriorated silicone oil 4

horsepower

conserve

Removal in to

equipped

conditioner

cover

silicone oil

filled with

used

as

a

which controls the fan oil can not be

fluid

speed replenished

special coupling

a

Silicone

I

CQ048

Fig CO 3 Removing water pump Torque coupling wheel Torque coupling cover 3 Torque coupling bearing 1

Installation 1

Be

sure

2

to clean the

gasket

sur

faces in contact with pump and front cover Always use new gaskets when

installing pump assembly

tighten

bolts

Be

sure

4

Pulley

5

Water pump C0060

to

Fig CO 4 Sectional view of torque coupling and water pump

00 3

Cooling System REMOVAL AND

DISASSEMBLY

INSTALLATION To

replace

follow the

The

the

torque

coupling

INSPECTION

torque coupling

is so

Inspect

designed

coupling for

torque

If necessary

leakage

that it can not be disassembled

oil

replace

procedure as in the water pump The torque coupling can not be separated from the water same

pump

TEM COUPLl

G

For air conditioner

equipped models

w I

6

1

Bi metal

2

Slide valve

3

Reserve chamber for

4

Bearing Driving chamber for ON ouplingpart labyrinth

5

6

thermostat OFF

coon

Fig CO 5 CrQM sectional view of

is

coupling Tem

coupling

which is

a type of fan provided with a

ation is

temperature control system The conventional

slips the fan

The

coupling always

installed the Tem

cooling requirement The

coupling with the ON

coiled

high speed under a regardless of the engine

at a

constant ratio

placed under OFF slips at about 1

and the fan

slipping

however is

of the Tern

properly changed

cooling requirement denotes that

cooling

of air

re

quired and

the front center portion of

relative to the engine coolant tempera ture and the inside slide valve is

opened is

bimetal

the

or

closed

ON OFF

as

required and thus

control

the fan operates up to about 2 150 rpm When high cooling is

When

required during cold season with the engine warmed up etc the oper

opened silicon oil

not

650 rpm thermostat

coupling detects temperature passing through the radiator air temperature is directly

The

ratio

on

condition

is

bimetal is

temperature rises the expanded and the valve is is forwarded to the

groove that transmits

4 CO

torque and the

placed under

ON

con

dition When the valve closes silicone oil is

supplied to the driving chamber driving chamber is accumu lated on periphery due to the centrif ugal force and led into the reserve not

oil in the

chamber

Now

oil is eliminated from

the driving chamber and the system is

placed under

OFF

condition

With this system when fan cooling

performed

the air

is

system

coupling Tem

is

not

required

minimized reduced

and

the noise

output loss can

be

is

far

Cooling System re After checking thermostat install with a new housing gasket in

4

place Conventional COUplin9 WATER PUMP SPEED

5

Reinstall water outlet

6

Replenish

should be

sure

that it is in

inspected to good condition

1

Measure

coolant

mostat

make

temperature

when thermostat valve starts to open 2

coolant and check for

Measure

lift

maximum

the

of

thermostat valve

leaks

INSPECTION

F Z

Tern

coupling

WATER PUMP SPEED C0029

Fig CO 6 Characteristic of Tern coupling

will

sticking thermostat

A

the

cooling properly If the open

prevent

system from functioning the thermostat sticks in

position the engine warms slowly If the thermostat the closed position over

up very sticks in

Fig CO S Impecting therm06t

heating will result Therefore the ther

INSPECTION

t

Check Tem coupling for oil leakage or

bend of bimetal

If the above symptoms replace it with a new

are

found

one

as

Valve

pellet type

cylinder head

temperatures

operating properly

moved and tested

as

type

iype

5 83

5 to 89 5 86

177 to 183

187 to 193

167

1 00 8

8 90

to

8 95 31 0

inF

203

if

and

should be

does

If thermostat the

not

operate

at

On

it

matic

must be

be

repaired

re

2

partially

Remove bolts and

gasket

models

with

equipped

transmission

combined with

auto

the oil cooler is

the

radiator to cool

transmission fluid

INSTALLATION

RADIATOR The radiator is

Disconnect upper radiator hose at

outlet

194

31 0

REMOVAL AND

water outlet 3

to 172

described below

INSTALLATION Drain coolant

212

31 0

specified temperature replaced because it cannot

above

REMOVAL AND

I

75 to 78

thermostat is

lating coolant temperature The ther mostat is designed to open and close at not

oC

mm

to control the flow of coolant facili tating fast engine warm up and regu

predetermined

type

80 5

Maximum valve lift

water outlet

The function of the

Tropical

is

thermostat

mounted in the thermostat housing at the

opening

temperature oC OF

THERMOSTAT wax

Frigid

an

assembly

A

Temperate

remove

water

and thermostat from

thermostat housing

flow

type

tanks

to

a

and

having top

bottom

distribute the coolant flow

uniformly through the vertical tube of radiator

The radiator filler cap is

kg cm2

designed

to

09 pressure pre set above psi atmospheric

a

13

pressure relief

The

valve

blow off valve and

helps

to

consisting a

the

prevent

vacuum

when

the

to

is

pressure

below atmospheric um

valve allows

pressure

air to

from

it How

reduced the vacu

re enter

the

radiator preventing the formation of a Fig CO 7 Removing therm06t

t

2

Disconnect

lower

vacuum in the

cooling system CO 5

con

hoses

radiator

upper

and

On models with auto disconnect cooler

inlet and outlet lines from radiator 3

Remove

bolts and

fan

remove

Remove front

5

Remove

and then 6

shroud

grille

radiator retaining bolts

remove

radiator

upward

Install radiator in the

quence

retaining

fan shroud

4

a

valve

coolant

boiling by giving pressure ever

of

clean

a

tainer

matic transmissions

core

maintain

Drain coolant into

conventional down

of removal

Note

reverse se

the

fol

lowing I

Insert

hoses in their positions

until they bottom 2 Ensure that hoses

are

clearly

arrow

marks

on

visible from upper

r

Cooling System direction when hoses 3

Ensure

that

are

radiator hose and any 30

mm

I

181

in

after cleaning it Then

assembled

clearance between

cap on

adjacent parts is

minimum On mod

will

a

not

sure

install radiator

tester If cap does not hold

If a leakage replace radiator

or

is detected

repair

or

release at the specified pres

replace

cap

els equipped with air conditions a minimum clearance of 18 mm 0 709 in

should

between

exist

compressor

and hose 4

Ensure

that

shroud and fan is Note

clearance between

even at

Be careful not to

fins and

tor

core

any

place

damage

radia

tube when in

stalling INSPECTION

Fig CO 9 Telting radiator

cap

Radiator cap should be checked for

working intervals cap for

pressure First

at

cracks

tears

regular

Also

inspect radiator for leakage using cap tester and applying a pres sure of 1 6 kg cm 22 8 psi

tune up

check rubber seal

on

deterioration

or

Fig CO IO Testing cooling 6ystem pUSure

SERVICE DATA AND SPECIFICATIONS Thermostat

Temperate

Frigid type

Tropical type

type Valve

opening temperature

oC

F

5 to 83 5 80

177 Maximum valve lift

mm

oC

inj

5 to 89 5 86

to 183

187

8 95

F

31 0

to

193

8 100 31 0

203

75 to 78

167

to

172

8 90 212

31 0

194

Radia tor

Type Manual transmission

Corrugated

fin


Corrugated

fin type equipped with oil cooler

Cap

relief pressure

type

kg em

psi

0 9

3 1

kg em

psi

1 6

22 8

Cooling system

Leakage testing

pressure

Capacity

with heater

Manual transmission Automatic transmission

8 0

liters US qt Imp qt liters US qt Imp qt

8 Ii

7 8 8 Y

without heater

7

74

i 6 J

7 2

Fan Number of blades

x

outer

diameter

Without air conditioner

mm

in

7

x

380

With air conditioner

mm

in

8

x

380

6 CO

15 15

i6 7J

1i

7 X 6 X

Cooling System


Condition Loss of water

Probable

Damaged radiator

Repair

seams

Leaks at heater connections or Leak at water Loose

Corrective action

cause

temperature

plugs

gauge

Repair Tigh ten Tighten

joints

Damaged cylinder head gasket

Replace Check engine oil for contamination and refill as

necessary

Replace

Cracked cylinder block

Check engine with water

Poor circulation

Corrosion

Cracked cylinder head

Replace

Loose

Tighten

cylinder

Restriction in

head bolts

oil

in crankcase

by pulling oil level

for mixing

gauge

Check hoses for crimps and clear the system of rust and sludge by flushing radiator

system

Insufficient coolant

Replenish

Inoperative

Replace

water pump

Loose fan belt

Adjust


Replace

Excessive impurity in water

Use soft

clean water

Rain water is satis

factory

Infrequent flushing and draining of system

Cooling flushed

system

should

periodically

Ethylene glycol base out

the

seasons

periodically Overheating


Replace

Radiator fin choked with mud chaff etc

Clean

Incorrect

ignition and valve timing

Dirty oil and sludge Inoperative

Adjust

Adjust

Restricted radiator

Flush radiator

Inaccurate temperature gauge

Replace Use soft clean water

in water


Replace

Inaccurate

Replace

temperature gauge

CO 7

and

be used

through change

and

passage thoroughly by using air from pressure engine side of radiator out air

Replace

water pump

can

of the year

Refill

engine

drained

at intervals recommended

Loose fan belt

Impurity

Overcooling

in

be

Permanent anti freeze

SECTION EF

ENGINE FUEL DATSUN PICK UP MODEL 620 SERIES

l NISSAN I NISSAN MOTOR CO TOKYO

LTD JAPAN

AUTOMATIC TEMPERATURE l CONTROL A T C AIR CLEANER

H

IDLE COMPENSATOR

H 7

FUEL FILTER

H 8

MECHANICAL FUEL PUMP

H

ELECTRIC FUEL PUMP

H ll

CARBURETOR

H 14

2

9

Engine

Fuel

AUTOMATIC TEMPERATURE CONTROL AIR CLEANER

A T C

CONTENTS DESCRIPTION

EF 2

VACUUM MOTOR

OPERATION

EF 3

CONTROL

A T C

AIR

CLEANER

HOT AIR

AIR

EF 3

CLEANER

HOT

AIR AIR

TEMPERATURE

COLD AIR EF 4

CLEANER

FRESH AIR

COLD AND

AIR

OPERATION

TEMPERATURE

EF 5

SENSOR

EF 5

VACUUM MOTOR

OPERATION A T C

EF 5


OPERATION AT C

AND AIR

VALVE

EF 4

SENSOR

EF 5

DUCT

EF 5

CLEANER

EF 6

INSPECTION

EF 5

EF 6

1

AIR

2

HOT AIR CONTROL

CLEANER

ELEMENT

EF 6 EF 6

SYSTEM

DESCRIPTION The air cleaner removes dust and dirt from the air before it enters the

and

carburetor and engine

sists of the

It also muffles

noise into

intake

resulting from the the engine

The air cleaner

of air

especially designed Tempera

Control Air Cleaner

reduce HC emission hood

the

In order to

when the under is

temperature

860F

below

automatic

control system maintains

at

30 to

thereby

540C

enabling

86

lean

carburetor calibration this twl

the

automatic

1

to

1290F for

setting n

addition

temperature

to

con

system is effective to improve warm up characteristics of the engine

between the exhaust manifold and hot

air cleaner system con

following

devices

is

be cleaned

Automatic

temperature

manifold

to

the

air

cleaner

Blow by gas filter The blow by gas nIter removes dirt and oil from the blow by gas sucked in

the air cleaner from the engine rocker

control

5

air cleaner

is actuated

vacuum

by

the air intake

Fresh

air

duct

Except

for

to control the intake

The fresh air duct leads the outside fresh air directly 6

air flow circuit The temperature sen

See 7

vacuum

models

passage Hot air duct

exhaust manifold

Page

on

the

The air warmed up

EF 2

tor

the air cleaner

paragraph

Idle Compensator

EF 7

Altitude compensator See

The hot air duct is mounted

to

Idle compensator

detects the temperature inside the air cleaner and opens or closes the sor

3

led

Canada

In the A T C valve

is

the hose

cover

air cleaner

control

duct

4

employed

viscous paper type It requires only periodical replacment and should not 2

air

through

Air cleaner element

a

300C

temperature the tempera

ture of air to be sucked in the carbure tor

carburetor icing

The air cleaner element

for improved exhaust emission control is referred to as Automatic ture

to remove

The A T C

California

paragraph Altitude Compensa Page EF 20

Engine

Fuel

@

1

Except for Canada

2

Fresh air duct Air inlet pipe

3

Vacuum

4

Air control valve

5

Hot air

6

Idle

7 8

Temperature

motor

assembly

pipe

compensator Blow by gas fiI teT Altitude

9

sensor

assembly

compensator

California models EF713

Fig EF

1

Automatic temperature control air cleaner

OPERATION The automatic temperature control system of the air cleaner is controlled

by

sensor

and the

vacuum

Under hood air

Sensor

vacuum

at

temperature

vacuum

the inlet air temperature and the

Air control valve

motor side

36 2

Below 300C

Sensor operation

operation

Open cold

inHg

Above 210 mmHg 8 27

air

Close hot air

inHg

30 to 540C

Half open cold air hot air

1290 F

Above 55 oC

Open cold

1310F

A T C

vacuum

Close

860 F

to

intake

by the engine

motor is actu

Below 60 mmHg

86

ated

load condition of the engine The inlet air temperature is detected by the

Open

Open

air

AIR CLEANER HOT

AIR OPERATION When the under hood air tempera ture is low the sensor air bleed valve

the

remains in the

urn

establishes

closed position

vacuum

passage

and

between

intake

motor With

manifold

and

this condition

vacuum

the

vacu

at the intake manifold side actu

ates the air control valve attached to

EF 3

the

motor

vacuum

duce

hot

through

air

the

into

hot

haust manifold

diaphragm the

to

intro

air cleaner

air duct on the ex

Fuel

Engine

A T C

AIR CLEANER

COLD AIR OPERATION

f

f

l

I Air inlet pipe Air

l ID

Cif

trol valve

con

The

Hot air pipe

in the

Diaphragm Vacuum hose

s 6

Diaphragm spring Air bleed valve

Ittl

closed

ID

Temperature sensor assembly

Holair

EF114

Fig EF 2 Hota

r

delivery

mode

When under hood air temperature

is low

During cold engine

operation

sensor

and

vacuum

passage is established between the in take manifold and the vacuum motor and the intake manifold

applied

the

to

is

vacuum

dia

motor

vacuum

phragm When the

vacuum

when the engine

is

is small or

operating under

1004 the air control valve opens widely irrespective of the temperature eavy

around the

sensor

to

introduce the

under hood air cold air for increased

7

power of the engine 2 When under hood air temperature To manifold Small

Dr

1

air Underhood

I

air bleed valve remains

closed position

@

is

vacuum

2

Air inlet pipe Air control

high The

valw

fully

sensor

air bleed

valve opens

to shut off the vacuum passage

3

Hot air pipe

4

Diaphnp

S

V leuum hoses

vacuum

6

Diaphragm prinl

vacuum

7

Air

air control valve closes the hot air

bleed

between the intake manifold and the

valve

closed

II

motor Due to the force of the motor

the

diaphragm spring

pipe

of the air cleaner and introduces the

Temperature

senSOr

assembly

under hood air cold air

EF20S

Fig EF 3 Cold air delivery mode During cold engine operation

A T C AIR CLEANER COLD AND HOT AIR OPERATION

f

liP

J

omanifold

1

Air inlet

2

Air

pipe

control valve

fully open Temperature assembly

8

EF715

ID f

R

fjr lfl

ow Air inlet

Hot air pipe

5 underh

pipe

Air control valve

2

Diaphragm

r

Vacuum hose

rv

Itti

Diaphragm spring Air bleed valve

ID

partially opened Temperature sensor assembly

air Hot

8

EF716

Fig

EF 5

Regulating

4 EF

air

delivery

mode

air

of the intake manifold

With the air

control valve

the cold air together and

and hot air sensor

Fig EF 4 Cold air delivery mode During hot engine operation

@

opening of the

control valve varies with the vacuum

Air bleed valve

@

air bleed valve is

partially opened

Diaphragm spring I

sensor

Diaphragm Vacuum hoses

Underhood air

When the

Hot air pipe

mixed for

perature

are

open half

sucked

controlling

of the air tem

of the air to be introduced to

the air cleaner

Fuel

Engine TEMPERATURE SENSOR

neeting

vacuum

hose to

sensor vacuum

The to the

temperature

sensor

2

into vacuum tube of

clip

Insert

After installing each hose secure hose with the clip

tube

sensor

is attached

vacuum

inside of the air cleaner The

bimetal built in the

detects the

sensor

position

is

R H

correctly

3 Fixed with

mark at the top side to Nissan of for intake manifold face sensor

adhesive

The

to install vacuum hose

sure

2 Calch

sensor

4 Hose

construction of the tempera

ture sensor is shown in the

Be

Note

Pipe

I

under hood air temperature and opens or closes the vacuum passage in the

5

following

Correct

L H side for vacuum motor

Tab

6 Clip 7 Gasket EC019

CD

V

00

@

I

I

Fig EF B Removal of semor 2

Disconnect hose from

3

Take off

clip

from

tube and dismount

VACUUM MOTOR

sensor

sensor vacuum

sensor

body from

air cleaner

2 I Protector

j @

1

I

Note

cover

Screw

Air

gasket

air cleaner is

Adjusting frame

1

The

cleaner side

temperature bimetal

Valve seat

between

and

sensor

bonded to the air and

should not

be

removed

Rivet

screws

Disconnect

securing

vacuum

valve shaft attached

to vacuum motor valve

control motor 3

frame

diapluagm from

and

assembly from

To

install

remove

air

cacuum

air cleaner

the removal

reverse

procedure

Inatallatlon

Lower frame

Remove

motor to air cleaner

Air bleed valve EF206

Mount

Gasket

Fig EF 6 Temperature

senior

sensor

on

the

specified

position For see

the

mounting position of

sensor

FRESH AIR DUCT

following I

VACUUM MOTOR AND

cleaner

AIR CONTROL VALVE

2

pressure which varies with opening of the carburetor throt The

the

diaphragm

carefully pull support while

shaft attached to

is then

moved up

or

be

introduced

into

the

provided

with

air inlet side end a

hand and

out from radiator core

turning

it

in

either

direction 3

To

install

procedure

Be

reverse sure

EF717

air

Fig EF 9

cleaner

lalling

se or

mounting hole port

the

removal

to insert

lions of fresh air duct

valve to control the temperature of the to

on its

Hold fresh air duct with

motor dia

vacuum

The valve

projections

down in response to the vacuum on the diaphragm This movement of the valve shaft actuates the air control air

Fresh air duct is

vacuum

tle acts upon the

phragm

Disconnect fresh air duct at air

projec securely into

in radiator core sup

to pr I

1

00

@

E F 207

Valve

2

spring Diaphragm

3

Retainer

4

Valve shaft

Fig EF 7 Vacuum

motor


Fresh air duct Air cleaner Duct mounting hole Radiator

TEMPERATURE SENSOR

Radiator

core

support

Removal EF518

Using

pliers

flatten

clip

Fig EF I0 Removal offresh air duct

con

EF 5

r Fuel

Engine AIR CLEANER 1

Loosen bolts

These air cleaner

securing

air control system

Loosen air cleaner lock bolt and

2

air

remove

Disconnect

cleaner from

carburetor

following

hoses when

the

malfunc

reveal

If these

check hot

occur as

described in the

following before carrying

out

inspec

tion of carburetor

air cleaner

dismounting

should

phenomena

air cleaner bracket

to

phenomena

tion of hot air control system

2 1

Vacuum

hose

Under hood air inlet hose Intake manifold

Hot air inlet hose Vacuum

hose

Sensor

to

intake

Vacuum hose

Sensor to

pensator

vacuum

um

motor

Vacuum hose Idle compensator intake manifold

Hose Carburetor Blow by hose

to

Air

hoses

vacuum

are

se

or

Vacuum

vaive

to

sensor

air

hose

Nissan

position

mark

RH

the top of is for intake manifold L U on

side of the mark is for

cleaner California models only To install reverse the removal

vacuum

Vacuum motor

1 AIR CLEANER

fresh air duct

Viscous paper type air cleaner ele does not require any cleaning

ment

operation until it is replaced periodi cally Brushing or blasting operation will cause clogging and result in enrich of

should

carburetor

never

be

refer to

mixture

conducted

placement interval of ment

With engine stopped Place

ELEMENT

above

at

disconnect

the end of air

condition

actuates the

spring

valve by its

control

In

de

replace

phragm

from

since

reo

motor as an

vacuum

this may be resulted

air leak at vacuum motor dia

2 3 Temperature

ensor

Check temperature

air cleaner ele

air

spring force to

under hood air inlet within 30

seconds

position

sensor

for func

tion

Maintenance Sched

by proceeding as follows Be sure keep engine cold before starting

to

test I

2 HOT AIR

In warm weather it

EF213

is difficult to

Fig EF 11 Inspecting valve position

find out malfunction of hot air control In

system

cold

wea

thee

With engine off check air control

valve for condition

CONTROL SYSTEM

2

however

Air control valve is in correct

posi

disconnection

and hot air inlet is closed

position

um

hose between intake manifold and

vacuum

bility

motor and insufficient dura

of air control valve will

insufficient

automatic

tion for intake air disorder I

cause

control opera

and result in

engine

including

Stall

or

hesitation of engine oper

ation

control valve 2

vacuum

hose

for condition

vacuum

and

motor

connect

inlet

another

hose to the inlet to apply vacuum to vacuum motor Vacuum can be ap

plied by breathing

in the hose end as

shown Place

Increase in fuel consumption uck of power

linkage

Disconnect

Check air

mirror

at

the end of air

cleaner inlet pipe and check to air control valve is in correct

6 EF

see

if

position

air control as

case

correct

valve

is

the

valve

for correct In

described above

position reverse

this

of air control

of 2 2 I

hood air inlet is closed

under and hot air

inlet is open 3 Check that air control valve grad ually opens to under hood air inlet side

a

mirror for

Immediately after engine starting check

deterioration of vacu

a

Start engine and keep idling

tion if its under hood air inlet is open

or

In this case under

hood air inlet is open Use inspection as 2 2 1 above

malfunction of air control valve due to

3

the

maintains

assembly

ule

2

hose

vacuum

check that air control

this condition

cleaner inlet pipe as shown and check to see if air con trol valve is in correct

and

For

in

described

and cut off air from

open

mirror

a

posi

paragraph 2 vacuum hose with fingers pinch

as

If diaphragm I

ment

tion

scribed in step 2 for more than 30 seconds and that hot air inlet is open

procedure

INSPECTION

position if

under hood air inlet is closed and hot

valve

motor

2 2

above Air

Jpar graph

air inlet is open 3 With hot air inlet in open

air cleaner

Note

is the reverse of

control valve is in correct

postion

Check each hose for cracks distortion hose clip for condition

Air cleaner to rocker

control

to vacu

Correct position of air control valve

connected in correct

side of

Hose

sensor

2

cover

3

temperature

Check that

curely

Hose Air pump to air cleaner Hose AB valve to air cleaner

Fig EF 12 Inspecting valve position

motor

I

to

EF217

temperature

3 way connector to idle com

sensor

manifold

3 way connec

to

3 way connector to

tor

as

engine

warms

up When

en

vironmental temperature around tern perature sensor is low spend more time for

engine warming

up

operation

Fuel

Engine facilitate smooth operation of air

to

element

will not be affected by air

flow Then install air cleaner

control valve

operation of

Remove

air cleaner

cover

Set

temperature around

be measured

thermistor bottom

test

as

described in When air

air

inlet side

several minutes

after engine starting

read the indica

tion of thermistor

thermometer If

or

tern

perature range of temperature sensor the sensor is normal If reading ex

sensor can

ceeds

fIx wiring of thermometer on the

In this case

or

out

2 and 3 above

reading falls within the working

temperature sensing element of ther mistor or thermometer to a position where

I

hood

air control

valve carry out the following test 4

Carry

control valve begins to open to under

If the above test reveals any prob lem in the

5

steps

cover

with

the range

replace

the

sensor

new one

surface of air cleaner with

adhesive tape in such a manner that the set position of temperature sensing

Note

Fig EF 13 Checking temperature

Before

replacing temperature

check idle compensator described in Idle compensator sensor

sensor

as

IDLE COMPENSATOR CONTENTS DESCRIPTION

EF 7


EF B

OPERATION

EF 7

INSPECTION

EF 8

DESCRIPTION

The

idle compensator operates in response to the under hood air temper

The idle compensator is basically a thermostatic valve which functions to

ature as shown below

introduce the air directly from the air cleaner

to

the

intake

manifold

q

to

compensate for abnormal enrichment of mixture in high idle temperature The

bi metal attached to the idle

compensator detects the temperature

1

Orifice

of intake air and opens or closes the valve Two idle compensators having

2

Bi metal

3

Rubber valve

different are

temperature

installed

temperature l580F

158

to

EF222

characteristics Fig EF 14 Structure of idle

opens at an intake air of 60 to 700C 140 to

one

and the other

at

70 to

compensator

900C

1940F

Bi metal

Intake air temperature Below 600C

OPERATION

No

60 to 70 C

1

140 The construction of the idle

pensator

is shown in the

com

following

1400F

OF

158

Below 700C

1580F

70 to 900C 158 to 1940F Above 900C

EF 7

operation

Fully closed Close to open

to l580F

Above 700C

No 2

Idle compensator

1940F

Fully open Fully closed Close to open

Fully open

Engine REMOVAL

Fuel Note

AND INSTALLATION

tor

When checking idle compensa on

leading connect

check 2

vehicle to idle

hose

disconnect

and

compensator

then carry out above

other hose bed descn

as

temperature is above the specified operating tempera ture visually check to see if the valve is in open position If valve is not When

bi metal

replace

open

idle compensator

as

an

assembly

EF718 Watcr

Fig EF 15 Location of idle compenl otor

Observe

temperature

valve

Remove air cleaner cover 2

Remove

hose

compensator and 3

Loosen

air If excessive air leakage is found at idle

connecting

3 way connector

screws

securing idle

pensator to air cleaner then idle compensator

com

pensators valve of

Notes

to

one as

to

11t

air cleaner

plug

the

of these idle compensa prevent air leak while

remove

gasket and plate screw securing

compensator

NO

2

70

to

metal Bi

900C

158to 1940F

EF226

@

idle

CD

install

reverse

the

I

removal

INSPECTION

3

Others

I

Check hoses for correct installa

tion distortion or cracks

tl

procedure

2

Check rubber valve seat of idle

compensator for sticking

faulty Check

closed

1

Orifice

position when bi metal temperature is lower than operating temperature To

2

Rubber valve

check

70De

to air cleaner be care

ful not to miss the saew

I

to

140 to 1580F

Fig EF 17 Checking idle compensator

removing idle compensator

b When removing

To

mounted

1 Bknctal

60

checking the other one

When

4

are

and that it is necessary to

remove

tors so

a

No

the valve replace idle compensator as an assembly Note that two idle com

tha t

valve

IS

m

breathe air into tube

or

suck

or

any other

conditions

EF225

Fig EF 16 Checking idle compelll

lor

FUEL FILTER REMOVAL

DESCRIPTION

Disconnect The fuel fJlter is

a

cartridge type

It

paper element which can be checked for condition from the out uses

inlet and

lines from fuel fJlter and

a

outlet fuel remove

fuel

fJlter

side 1 2

Body Paper element

3

Cover

Fig

1

EFOO5

EF 18 Sectional view ofcartridge

type fuel filter

EF 8

Note

Before disconnecting fuel lines container to receive the fuel

use a

remaining in lines

Engine

Fuel

MECHANICAL FUEL PUMP

CONTENTS

DESCRIPTION

EF

9

REMOVAL AND

FUEL PUMP TESTING

EF

9

INSPECTION

EF 10

EF

9

ASSEMBL Y

EF 11

TEST

STATIC PRESSURE

CAPACITY TEST

DISASSEMBLY

EF 10

EF 10

DESCRIPTION

1

The fuel pump transfers fuel from the tank to the carburetor in sufficient

quantity

the engine require speed or load

to meet

ments at any

The fuel pump is sists of a

fuel

a

pulsating type

easy maintenance

designed for

It con

body a rocker arm assembly diaphragm a fuel diaphragm

a

spring

seal inlet and outlet valves

Figure

EF 19 shows

a cross sectional

view of the pump

The

fuel

specially

affected by

by

consists

diaphragm

gasoline

of

which is not

treated rubber

and held in

two metal discs and a

pull

place

rod 1

Outlet valve

2 3

Diaphragm Diaphragm spring

4

Inlet valve

S

Rocker

EF006

ann

Fig EF 19 Schematic view offuel pump

FUEL PUMP TESTING A fuel pump is

when its

operating properly

pressure is within

tions and its

capacity requirements Pressure and capacity engine

s

mined

by

is

specifica

equal

at

all

to the

speeds

must be deter

while the pump is the engine Be sure

two tests

still mounted

on

there is fuel in the tank when carrying out the tests

STATIC PRESSURE TEST The static pressure test should be made as follows I

Disconnect fuel line between

Note

Locate

this

Tconnector

close to carburetor as

as

possible

car

buretor and fuel pump

2

Connect

a

rubber hose to each

Connect a suitable pressure gauge the opening of Tconnector and fasten hose between carburetor and 3

open end of a T connector and con nect this connector hose assembly be

to

tween carburetor and fuel pump

T connector with

EF 9

a

clip securely

Engine Fuel 4

Run the engine

5

The

at

varying speeds indicates

gauge

pressure

2

Take off cap and cap gasket by

removing cap

screws

fuel pressure in the line The gauge reading should be within the

3

Unscrew elbow and connector

4

Take

following

screwing

static

range

5

3 0 to 3 8 psi

To

remove

down its center If the fuel in carburetor float

Note

chamber has

run

out and

engine has

and pour fuel

stopped

clip

into carburetor

Fasten

clip

secure

1 static pressure test

ly and repe

retainer

by

J

un

retainer screws and re

move two valves

kg em2

0 21 to 0 27

off valve two

With

diaphragm press against spring force

diaphragm pressed

down

tilt it

until the end of pull rod touches the inne

wall

of

body

Then

EFOO7

release

diaphragm

Be

careful

to unhook push rod during this operation not damage diaphragm or oil se L

to

Fig EF 20 Remouing pull rod 6

Drive rocker

press

or

arm

out with

pin

a

hammer

Pressure below the lower limit indi cates extreme wear on one

part or a small amount of wear working part It also indicates ruptured dia phragm worn warped dirty or gum on

seats

ming valves and

diaphragm above

return

i

each

or

spring

weak

a

Pressure

the

upper limit indicates an excessively strong tension of dia

phragm

return

that is too

spring

a

or

8

diaphragm

Both of these condi

tight

require the removal of pump assembly for replacement or repair tions

o

TEST

CAPACITY The when

capacity

test

is

made

only

6

static

pressure is within the specifications To make this test pro ceed as follows 1

Disconnect

install

a

in its

vacant

suitable container

as

8

Cap gasket Valve packing

4

fuel pump

e val

S

Valve retainer

6

Diaphragm assembly Diaphragm spring

7

8

fuel

sump Run engine at 1 000 rpm 2 3 The pump should deliver 1 000

3

assembly

place a

fuel pump cap

7

pressure gauge from

T connector and

I 2

9

PuRro Lower body seal washer

10

Lower body seal

11

Inkl connector

12

Outlet connector

13

Rocker

arm

14

Rocker

arm

fuel flows from the

IS

Rocker artyl side pin

open end of pipe it is an indication that fuel line is clogged or pump is

16

Fuel pump packing

17

Spacer fuel pump fo cylinder block

11 2

US pt of fuel in

one

minute

cc or

less If little

or

no

malfunctioning

spring

EF510

@

REMOVAL AND

Fig EF 21

offuel pump

ure Slruc

DISASSEMBLY Remove

fuel

unscrewing

two

disassemble in the 1

pump assembly by mounting nuts and

following

2

INSPECTION

order

Separate upper body and lower body by unscrewing body set screws

valve I

Check

upper body and

lower

Check valve assembly for and valve

assembly with brea th function

body for cracks

EF 10

spring

wear on

Blow

valve

to examine its

Engine Check

3

carcks 4

6

arm

for

wear at

the

Reverse the order of

with camshaft

Check rocker

pin

To test the function

proceed

as

follows

mating portion worn

3

ASSEMBLY

or wear

Check rocker

5

for small holes

diaphragm

Fuel

pin for wear A leakage other components for

any abnormalities and

replace

if

I meter

instruc

tions

arm

may cause oil

Check all

Position fuel pump assembly about 3 ft above fuel level of fuel

disassembly

Closely observe the following L 2

strainer

Use

new

Lubricate rocker

link and rocker

neces

arm

ann

connect

Operate rocker

rocker arm

a

from

pipe

arm

by hand Iffuel

is drawn up soon after rocker arm is

pin before installa

released

tion

sary

and

strainer to fuel pump

gaskets

fuel

is

pump

functioning

properly

ELECTRIC FUEL PUMP CONTENTS DESCRIPTION

EF 11

DISASSEMBLY

EF 12

INSPECTION

EF 11

ASSEMBL Y

EF 12


EF 12

TROUBLE

DIAGNOSES AND EF 13

CORRECTIONS

DESCRIPTION The electric fuel pump is on

air conditioner

adopted

equipped

models

The silicon transistor type fuel pump consists of a transistor diodes a sole

noid

a

pump mechanism and filter

parts

J ev J

I

Tr

lOsistor

6

Ou tIet valve

2

7

Return spring Filter

3

Plunger Diaphragm

4

Diode

5

Magnet coil

8 9 10

I

T

2

Re

nsistor

3

Dinde

4

Signal

5

Main coil

I

f ist

coil

3

6

Resistor

7

Zener dlOdl

8

Resistor 2

Magnet EF719

Inlet valve

Fig EF 22 Construction of electric fuel pump

INSPECTION I

Disconnect

fuel

hose

at

pump

outlet 2

meter

If diameter is too small

6

a

mm

suitable hose 0 24

in

approxi inner dia

the

proper delivery capacity cannot be obtained even if pump functions properly

following

Connect

mately

Note

to pump outlet

3

a

than pump

15 seconds 4

EF 11

With hose outlet in

higher posi operate pump and check delivery capacity for more than tion

The capacity should be I 400

cc

Engine Fuel 854 co in in one minute If

no

gasoline

or

b Do not let

less

only a little flows pipe with pump

or

open end of operated or if pump does not work from

c

perform the following diagnosis Notes 3

battery

Do not connect

which

polarity

would

time

a

Fuel

long

it may

46

kg cm

ASSEMBLY I

Before assembly

clean all parts

with gasoline and compressed air

com

pletely Notes a

maximum

pressure

0 32

transitor

damage

as

tronic components

in reverse

if left for

fall pump

damage electronic components max Do not apply overvoitage l8Y Overvoltage starting by tage running quick charge or would deteriorate or damage elec

If

t an d fdterare faulty gask

r

place

psi

b Clean magnet and cover for fault c Take care not to defonn thin tube

circuit and disable pump

d Assemble


plunger

inlet valve To carburetor

spring e

spring

return

Oring washer and set

retainer in that order

Assemble filter

gasket and

cover

with f

Tighten

cover

with wrench to the

stopper If component parts are dirty after disassembly clean as follows 2

Elecuic fuel pump Mounting bracket

3

Fuel mter

1 Flom

fuel tank

Wash fIlter and strainer with clean

gasoline

Wash

Fig EF 23 Electric fuel pump

located

on

R H side member

adjacent

to fuel tank

Remove

I

pump to

ning

Also

inlet remove

engine

hose

fuel

from

outlet hose

Receive fuel remaining

in fuel hose in a suitable container

2

Disconnect harness

3

Remove bolts securing fuel pump

at

connector

to bracket and detach fuel pump

Installation is the reverse order of

4

cover

cover

with wrench and

gasket

magnet

filter from pump body 2 When removing plunger

and

Then

out

take

inlet valve return

washer

spring

and

O ring

plunger

Do not disassemble electronic If

n

replace

new ones

9 6

@ Cover

8

Oring

2

9

Inlet valve

3

Magnet Cover gasket

10

Retutn PIing

4

Filter

11

5

Gasket

12

Plunger Plunger cylinder

6

Spring retainer

13

Body

7

Washer

v

EF721

Fig EF 24 Exploded view of electric fuel pump EF 12

m lI

parts for

wear

they

are

found faulty

replace

them 3

Insert

assembly

into

cylinder of body and

apply

plunger

electric current to it Move the assembly up and down If the assembly does not move it shows that the electric uuit is and it must be

from tube

with

c

damage

plunger take out

spring retainer from plunger tube 3

Check

If

Remove

components

1

or

faulty

Note

removal

2

Do not disassemble unless pump is

take out run

inlet valve with clean gasoline and blow dust off with compressed air

DISASSEMBLY

I

cleaning parts check replace plunger plunger cylinder and

fllter for fault If faulty

EF72D

Electric fuel pump is installed on bracket with two bolts This bracket is

and blow with compressed

When

air

replaced

faulty

Engine

Fuel


Condition

Fuel pump fails to

Terminals

operate

Rust

on

Frozen

or

Corrective action

cause

Retighten

connections loose

terminals

liquid

in

or

grounding

plunger

or

Clean

metal

Clean

pump

plunger assembly

plunger is stuck

or

Replace

pump

if

seized

Fuel pump fails to discharge sufficient

Clogged filter

Clean pump interior Clean and if necessary replace fIlter

flow

Insufficient fuel

Replenish

Insufficient fuel

Air in fuel hose

Apply

through connections

discharge during high speed travelling Low float level at

idling

a

coating of end sealing compound

connections and

Hose necked down tank

Fuel

or

breather

Check and correct

bent

tube

to

retighten

bent

or

necked

Check and correct

down

Replace

Weakened return spring sucked through connection

Fuel pump is actuated

Air

more

and fuel pump joint

frequently

than

Fuel hose

under normal condi

Clogged

tion

Rattling

noise

on

suction side

fuel hose

Apply

a

coating of end sealing compound

connection and retighten Check and correct

bent

Clean

fIlter

or

replace fIlter

Retighten

Mounting bolts loose

EF 13

to

Engine

Fuel

CARBURETOR CONTENTS DESCRIPTION

EF 14

CHOKE

EF 14

ELECTRIC

PRIMARY SYSTEM

EF 15

INTERLOCK

OPENING OF

SECONDARY

EF 16

SECONDARY

THROTTLE

EF 17

DASH

EF 18

ACCELERATING

STRUCTURE

AND OPERATION

SYSTEM

ANTI DIESELING FLOAT

SYSTEM

SYSTEM B CD

ELECTRIC

D

AUTOMATIC

CHOKE

DASH POT SYSTEM ALTITUDE

AND

VALVE

EF 24

POT

EF 25 PUMP

EF 25

SOLENOID

BC D D

EF 20

TEST CONNECTOR

EF 20

ALTITUDE COMPENSATOR

CIRCUIT WITH

VALVE

EF 25

FUNCTION EF 25

EF 29

California modelsl MAJOR SERVICE OPERATION

EF 20

ADJUSTMENT AND INSPECTION MIXTURE

EF 24

PRIMARY

EF 1B

COMPENSATOR

California models

CARBURETOR

EF 23

AUTOMATIC CHOKE

ANTI DIESELING

BOOST CONTROLLED DECELERATION DEVICE

UNLOADER

EF 29

REMOVAL

EF 21

EF 29

DISASSEMBLY AND ASSEMBLY

IDLE RPM AND

RATIO

CLEANING

EF 21

EF 30

AND INSPECTION

FUEL

LEVEL

EF 22

SERVICE

FAST

IDLE

EF 22

TROU8LE

DATA

VACUUM BREAK

EF 23

CORRECTIONS

EF 34

AND SPECIFICATIONS

EF 35

DIAGNOSES AND

DESCRIPTION

EF 36

STRUCTURE AND

OPERATION The carburetors two barrel

optimum

are

of down draft

types which produce the air fuel

mixture

under all

operating conditions They

present

several

features of importance

to

distinct

the vehicle

summary

of the features is

as

follows 1

A

slow

economizer

smooth connection or deceleration

to

make

a

with acceleration

during light

load run

ning It

also

assures

stable

low speed

performance 2

A

BC D D

hydrocarbon 4

An

5

6

An

to a

minimum

These

reducing

emissions

electric automatic choke to to

reduce

dieseling solenoid dieseling run on

to

A

The

float system

accelerating

comes

equipped

of

common

to both

mechanism

etc

are

a

power

dieseling valve

mechanism

under all

pensator corrects air fuel mixture

pensator is installed in the California models

EF 14

an

also

also

are

installed

com

se

solenoid valve and

with dash pot which ensures smooth deceleration without engine stall

operating conditions The hand operated altitude

a

attached An anti

carburetor

consist

primary and secondary systems a condary switch over mechanism

speed operation 7

carburetors

primary system for normal running and a secondary system for full load running A

anti

power valve or vacuum actu ated booster to ensure smooth high

8

An idle limiter to reduce harmful

exhaust emissions

H C

device for

facilitate cold starting and exhaust emissions

eliminate

owners

A

3

The

an

hand operated altitude

optimum

ratio

com

to

Engine

Fuel

jli@ I

tZrJ

I

III

@

Fuel nipple

I

2

Fuel filter

3

Needle

4

Float

S

Primary

6

Idle

7

I die hole

12

Air bleed

19

Choke valve

25

8

Primary bypass hole

Secondary

13

Primary slow jet

20

26

Secondary small

9

Primary throttle valve Primary altitude compensator pipe California models Secondary altitude compensator pipe California models

14

Primary small venturi High speed enricher air

27

D C D D

bleed

28

Secondary

10 11

main

adjust

Do not

Note

jet

screw

remove

Plug 15 Primary 6 Primary 17 Primary 8

the parts marked with

21 slow air

bleed

main air bleed

22

Richer nozzle

air vent

pipe

23

Primary main nOlzle

24

Richer jet Secondary

an

air vent

a

main nozzle enturi

sembly throttle valve

pipe

EF722

asterisk

Fig EF 25 Sectional view of carburetor

PRIMARY SYSTEM main Prlmar

sstem

The

primary main system is a Stromburg type Fuel flows as shown in Figure EF 25 through the main jet mixting with air which comes in from the main air bleed and passes through the emulsion into

tube

venturi

the

and is

through

pulled the

into the

the idle hole and

and

engine through the idle hole bypass hole Adoption of the submerged type of slow jet eliminates such hesitation as

sow

occurs on

nozzle

sudden deceleration of the

Slow

economizer

system

smooth deceleration at high

obtains Accele atlns mechanism

speeds

Small opening of the throttle valve at

idling

vacuum

or

partial

load creates

a

large

pressure in the intake mani

sstem

low engine speed as shown in Figure EF 25 fuel flows through

During

By this vacuum pressure fuel is measured through the slow jet located behind the main jet And air coming from the 1st slow air bleed is mixed

the slow jet located on rear right side of main nozzle mixing with air com

with fuel in the emulsion hole

ing from the 1st slow

atomized with air coming

mixing with slow air

air bleed

again

coming from the bleed and then is pulled air

2nd out

This mixture is further mixed and

2nd

slow

mixture is

air bleed

supplied

to

EF15

The

from

the

atomized

the engine from

equipped

The carburetor is

piston linked

fld

IdUns and slow

hole via the

vehicle

out

main

bypass

sysem passage

accelerating

type to

the throttle valve

throttle

primary Figure EF 26

is

valve closed

with the

mechanism

When the shown the

in

piston

and fuel flows from the float goes up chamber through the inlet valve into

the space under the piston When the throttle valve is opened the piston goes

and

down

opening

the outlet valve

fuel is forced out

injector

through the

Fuel

Engine

1

L

if

1

Pump injector

2

Piston

3

Spring Weight Damper spring Piston return spring

4

5 6 7

8

Inlet valve Outlet valve EF023

Fig EF 26 Acceleration mechanism

Power valve mechanism The called

valve mechanism

power vacuum

vacuum

SECONDARY SYSTEM so

piston type utilizes the

below the throttle valve

When the throttle valve is

opened during light vacuum

fold

is created in the intake mani

This

piston

load

slightly running high

pulls the against the

vacuum

upward

vacuum

spring

leaving the power valve closed When the vacuum below the throttle valve is lowered

during

full load

or

Secondary

main lIYlltem

pulled

out

through

the main nozzle

into the small venturi The secondary main

system

is

Due to the double venturi of the

a

Stromburg type

secondary system

Fuel air mixture

produced by the

functions of the main

jet

bleed and emulsion tube manner as

in the

main

air current

air

velocity

passing through the main

nozzle promotes the fuel atomization

in the same

primary system

the higher

The structure is almost the

is

same as

the primary side

accelerat

ing running the spring pushes the vacuum piston downward opening the power valve to furnish fuel

1 11

I 1

1 2

Primary vacuum port Secondary vacuum port

3

Diaphragm chamber cover

I 1

1

Vacuum piston

2

Power valve

a ET02

Fig EF 27 Sectional view of po

11

ll W l v

of S 6

Diaphragm spring Diaphragm Secondary throttle valve

7

Primary theo nle valve 512 EF

r

valve

Fig EF 16

EF 28 Full throttle al high peed

Fuel

Engine HI

Step system

richer

jet

high speed

bleed

and richer nozzle

The The

construction

of this system

correspond to the idling and slow system of the primary system Tlris system aims at the proper may

filling

high speed

h speed circuit circuit

improves

high engine output performance during high speed driving This circuit operates only when driving at high speed It consists of a

velocity of the

air

When the

suction air

flowing through secondary bore in

carburetor

creases

enricher

additional

fuel is drawn out of

the richer nozzle

up of the gap when fuel

supply primary system to the secondary one The step port is located near the secondary throttle valve edge in its fully closed state is transferred from the

@

2

Secondary switchover mechanism The

throttle

secondary

linked

to

actuated

the the

by

diaphragm vacuum

valve

is

which is

created in the

jet provided at and secondary primary venturies and the composite vacuum of these jets actuates the diaphragm As the linkage causes the secondary throttle valve to close until the prima ry throttle valve opening reaches ap proximately 500 fuel consumption during normal operation is not exces venturi

A vacuum

is

each of the

sive

During shown in at the

high Figure

venturi

speed EF 28 is

running as

EF234 as

the vacuum

increased

Secondary

Primary

the dia

is pulled against the diaphragm spring force and then secondary throt

The

Richer jet

High speed

enricher

air bleed

phragm

tie valve is

I 2

3

opened

Richer nozzle

Fig EF 29 High speed circuit

other side

during low speed running as the primary throttle valve the opening does not reach 500 secondary throttle valve is locked to close completely by the locking arm which

is

interlocked with

throttle

arm

primary

ANTI DIESELlNG SYSTEM The carburetor is equipped with

is an

dieseling solenoid valve As the ignition switch is turned off the valve anti

brought

into

operation shutting off

the

supply of fuel to the slow circuit The following figure shows a see

tiorial view of this control

by linkage

the primary throttle valve opening reaches wider position than 500 the secondary throttle valve is When

arm

CD

open because the locking revolves and leaves from the se

ready

to

condary throttle

1

g

1

arm

@eI EF230

1

dieseling Anti

solenoid va1

2

Ignition switch

3

Battery

@

l Fig EF 30 Schematic drawing of anti dieseling sydtm

EF 17

Fuel

Engine FLOAT SYSTEM

determined duces

There while

Jnd stl

only

IS

two

one

float

chamber

arburetor systems primary l

ondary

provided

are

Fuel fed from the fuel pump flows through the filler and needle valve into

flo

the level

t

chamber

is maintained

A

constant the float

by

fuel

fuel

will

consumption

fluenced by

quantity into the manifold by opening a separate

mixture

be

not

in

dirt accumulated in

some

the air deaner

of H C

amount

its

considerably long use Besides the of a spring wiU prevent the at flooding rough road running inserrion

the

carburetor

During

vacuum

takes

contained in exhaust

the transition to a

idling signal which

period from

the transmission turns on the

opening the

vacuum

engine speed

the

to

predetermined idling transmission

serves to

it

and

amplifier

hydrocarbons He gine during coasting The

en

consists

of B C D D valve

solenoid

during

vacuum

vacuum con

and

fold

vacuum

reduced

@

This

to

be

result that bons

a

large

amount of

is emitted into

hydrocar tile atmosphere

The B C D D has been correct

designed

to

this problem

It opern tes manifold

as

vacuum

exceeds

when the a

pre

the

at

of mixture

amount

the

upon

pre

coasting

depends bleed

air

while the mixture ratio is deter

mined

by

coasting

the

@

coasting jet

@

bleed

air

See

and

Figure

EF 31

Vacuum control solenoid

Manual transmission models The vacuum control solenoid valve con

troDed

by

speed

a

as

a

when the

fetermined pre

As the vehicle speed falls below 10 this switch is activated pro

causes

the manifold into

introduced chamber

and

the

acts so

open the

actuates the

vacuum

control

solenoid valve

second

actuates

Automatic transmission models

valve

vacuurn

dia

phragm ll@ When diaphrngm

II operates the valve @ opens the

passage and introduces the additional mixture into the manifold

EF 18

to

vacuum

value

to open the vacuum control

vacuum

detecting

switch that is actuated by the speed ometer needle

amplifier

I Qj monitors the mani and

mixture control

follows

kept

ducing a signal This signal

exceeds

of mixture per cyl inder per rotation of engine with the

The

mainly

inhibitor

BC D D operation

coasting prevents the mixture from complete combustion because of the amount

may

that the manifold

MPH

Diaphragm

high manifold

so

be

determined value

is

reduce the

emitted from

@

models

On automatic transmission models trol

BC D D

vacuum

of the

and vacuum

valve operation manual

On

Boost Controlled Deceleration

Device

control valve

CID

con

chamber to

switch A

mixture control valve

action

the atmosphere The mixture control valve is then closed returning the

BOOST CONTROLLED DEVICE

by

servo

the valve is lifted off its

place

tecting switch

B C D D

the

control solenoid valve As this

this system consists of B C D D vacuo urn control solenoid valve speed de

DECELERATION

The amount of the mixture is

trolled

II@

dramatically reduced

coasting produces

seat

The needle valve includes special hard steel ball and will not wear for all

in

passage

Complete combustion of fuel is assist ed by this additional mixture and the gases is

Because of the inner air vent type of the float chamber ventilation the

intro

mixture ratio and

mum

and

needle valve

the B C D D

value

additional mixture of opti

an

When P

the shift lever is in

position

mounted

on

the

inhibitor

N

or

switch

the transmission turns

on

to open the vacuum control solenoid

valve

Fuel

Engine

I

Secondary main jet Coasting jet 14 Coasting air bleed I 12 13

Air

2

jet Diaphragm

3

Mixture control valve

4

Coasting

5

Mixture air

II

air

bleed II

15

7

16

8

Boost passage

17

9

Vacuum control

6

N

Inhibitor switch

ON

passage Secondary baHel Intake manifold

P

for automatic

transmission

solenoid

Amplifier Speed de tecting 10 M P H

ON

valve

swi tch below


10

Vacuum control

II

Diaphragm

valve

18

Ignition

CID

switch

I

11

6 I

@

fI3 r 101

1

j

W

@ i r

@

JJ

I

t

i

J

l

J Note

Broken line

applies only to Automatic Transmission

EF231

Fig EF 31 Schematic drawing of B C D D

I 2

3

Ignition switch Amplifier Speed detecting switch 10 M P H

ON

Inhibitor

switch


below


ru I

4

ON

N

r

p

lJ

for automatic transmission

5

Solenoid valve

6

Vacuum control valve

7

Altitude corrector

i7

I

To intake manifold

1 J To air cleaner

I

LlJ

I

l

f

L8

J

l E F235

Note

Broken

line applies only to Automatic Transmission

Fig EF 32 Schematic drawing of RC D D

EF 19

California models

Fuel

Engine The

ELECTRIC AUTOMATIC

each

CHOKE

construction and function of of this carburetor

part

are

as

bi metal

which

mixture ratio

controls the

air fuel

required for starting

follows An electric heater wanns a bi metal interconnected to the choke valve and

controls the position of choke valve and throttle valve in accordance with the time

the

elapsed engine

tion of the

warm

up condi

and the

outside

ambient temperature When outside ambient temperature is

above

operating temperature

the

automatic choke control serves to fur

ther

reduce

during

exhaust

warm

selecting

one

tion modes

by

up

of the

gasemission automatically

two choke

fast acting

or

opera

slow acting

Slow acting choke operation When ambient temperature is low electric

current

automatic

to

through

the

choke relay to the P T C

heater A bi metal

flows

and This

gradually causes

warms

l

Electric

ttea

r

and

heater

in

choke

tl 1SI nd war The deflection of the

engine

bi metal is

transmitted to the choke

valve through the choke yalve lever 2

fast idle

opening of

cam

determines the

the throttle valve so that

the proper amount of mixture cor responding to the opening of the choke

valve

opening of ent

upon

the

engine

3

obtained

will be

the choke valve is

the

warm

The

depend

up condition

Fast idle adjusting This

of

4

choke

the

liUle

period that is before the

valve

so

as

obtain

to

an

adequate

air fuel mixture 5

Fast acting choke operation

the

When ambient temperature is high bi metal switch is in on This

causes

the

PT C

ing

electric current to flow through

automatic

in

choke

relay

to

heater A and heater B

the

result

quick opening of the choke

valve

diaphragm enginThas been started by cranking this diaphragm forces the choke valve open to the predetermined so

as

to

provide

the

proper

air fuel ratio 6

metal Bi

The used

link

pot engine stall resulting from quick application of the brake or from the quick release of the accele ra tor pedal after treading it slightly In such a situation

a

throttle lever

strikes against the dash pot stem and makes the primary throttle valve close thus

gradually running

keeping

the

engine

ALTITUDE COMPENSATOR

The higher the altitude the richer the air fuel mixture ratio and there fore the higher exhaust gas emissions

though the engine is properly ad justed for low altitude driving even

Vacuum

After the

extent

a

is intended

engine during

opens sufficiently this unloader forces the choke valve open a

open slowly

through

The dash

California models

accelerating

the warm up

ked wi h the interl

throttle valve

primary

mechanism

equipped

are

screw

U nloader

When

carburetors

adjusts

the opening of the throttle valve of the fast idle earn screw

These

with a dash pot

to prevent

Fast idle cam The

DASH POT SYSTEM

flows through the

current

le t

as

bi metal

the

the

the choke valve

Bi metal

cover

The altitude compensator is design to meet EiiriSSion S13ndards for

ed

driving in both low and high altitudes At high altitudes additional air is sup plied to the carburetor by the altitude compensator

case metal bi

index mark case

index

When the altitude

pensator lever is set at mark

is

for setting the moment of the

D

H

com

air is

conducted through an air passage to the carburetor The air passage is closed when the lever is set at L

H L Lever

When operating the H L lever fol

r

low these instructions

Il H

@@ r

position

Should be used for EF232 1

4

@

Automatic choke

P

T C heater

cover

Bi metal switch

6

P

7

Bi metal

8

Choke valve

B

Fig EF 33 Schematic drawing of electric automatic choke heater

EF 20

Counties

L position

A

5

T C heater

general driving designated by law as

relay

Automatic choke

3

areas

High Altitude

Alternator

2

in those

For nated

use

as

outside those

areas

High Altitude Counties

desig

Fuel

Engine

a

1 219

b Counties

Notes

The idle rpm and CO vary accord ing to the altitude Therefore they

properly adjusted the position of the H L lever changed

4 000

m

sea

level

designated by law

when

should be

above

more

High

as

ft

Altitude

For further details

Counties

or

have been

shown in Figure EF 35

the dis

Plug

connected hose to prevent dust from

entering

refer 0

to 1977 OATSUN PICK UP Service

is

Bulletin Pub No 257

o

n

Air cleaner

0

I

rID

Low altitude

Ll

n

If

mOl

EF259

n

L

Fig EF 35 Disconnecting air hose from air check valve

6

Race

two

or

I 500 to 2 000 rpm

engine

three times under no load then

engine for one minute at idling speed 7 Adjust throttle adjusting screw until engine is at specified speed run

Engine speed

Fig EF 34

EF729

Manual transmission 750 rpm

probe into tail pipe 40 em 15 7 in sert

ADJUSTMENT AND INSPECTION

more


than

0

in

position

650 rpm

CARBURETOR IDLE R P M AND MIXTURE RATIO

Idle adjustment with CO 8

CO meter

If


neces

adjust it to specifications This operation need not be carried

sary

Idle mixture the

Cautions 3

On

ped

automatic transmission models

equi

check should be per

formed in the

0

Be sure to engage

position parking brake and

to lock both front and rear wheels

Keep

your foot down

on

the brake

pedal while depressing the accelera tor pedal Otherwise vehicle surges forward dangerously

00 not

attempt

adjusting Ooing

so

could

to screw the idle

completely damage to tip

down

screw

cause

which in turn will tend to

cause

When

idle

it

adjust

mixture

have the meter

preparing

I

2

120 750 750 100

Check carburetor pipes for proper water

specifically mended Either driving vehicle is

3 ture

Make

not

at no sure

recom

that water tempera

adjustment

has

been

speed Ouring this 10 proceed as described in steps

minutes

5 to 9 below

mission

connector

5

screw

so

that CO percentage

specified level

tl 2

at 750 rpm

Automatic transmission in

0

position

tI 2 10

at 650 rpm

Repeat procedures

as

7 and 9 above

in steps 6

described

so

that CO

level Check

Remove air hose between 3 way 5 way connector for Cali

fornia models

engine adjust idle

CO percentage Manual transmission

applying load to engine in order to engine condition Engine

made shift the lever to the N or P position for automatic trans d When measuring CO percentage in

is at

stabilize

idling

position

idling speed

at

run

adjusting

Further keep engine running at about 2 000 rpm for about 5 minutes with

at

California

At about 10 minutes after

9

indicator points to the middle

Idle Limiter Cap

Non California

rpm

120 650 rpm

is

or oper load will be good

0

in

perature indicator points to the middle of gauge The procedure to warm up

engine

rpm


tem

To install idle limiter cap refer to

idle

Manual transmission

thoroughly warmed up

Warm up engine until

1 000 miles service

Ignition timing

is essential to

hood should be open Run engine for about 10 minutes 4

After

out at 1 600 Ian

to

and calibrated

out

malfunctio11ll b If idle limiter cap obstructs proper adjustment remove it

c

adjustment requires especially for

CO meter

California models

ating engine

Notes a

a

connection

with wheel chocks b

of

use

and air check valve EF 21

as

percentage is at specified ing idle CO in step 9 can be carried

right after II

out

step 7

Race

engine 1 500

to

2 000

Fuel

Engine two or three iimes under

rpm

and make

that

sure

no

is

load

CO per

specified

adjusting

centage is obtained 12

10

hose to air check

valve

engine speed increases readjust it the specified speed with throttle

Repeat procedures

speed for

COidle edJustment without

CO meter

not

is

following procedures

available

may be used

Warm up engine until water tem perature indicator points to the middle The procedure

mended Either 3

to

specifically driving vehicle

at no

indicator points

to

keep engine running for

stabilize

to

without

in order to

engine

condition

engine

should

hood 4

about 5 minutes load

applying

about 2 000

at

Engine

be open

in

D

Remove air hose between 3 way 5 way connector for Cali and

air

valve

3

Float chamber

If engine speed increases readjust it to the specified speed with throttle

4

Needle valve

adjusting

Do

not remove

necessary

moved

check valve

Plug the dis

I

After

engine 1 500

three times under

to 2 000 rpm no

load then

engine for one minute at idling speed 7 Adjust throttle adjusting screw so that engine speeds are as indicated

throttle

adjusting speed adjusting screw

standard

Race

To

readjusted at lime adjust proceed as

2

amount

gases

or

idle

check to be

sure

of CO

meets

contained in

float

Adjust bottom

that clearance

this idle limiter cap If this unit is re

it must be

that the

IIf I t

ET032

Fig EF 37 Adjusting float level 2

unless

seat

screw

Idle limiter cep

exhaust

or

it

Float

entering two

I

Float

connected hose 19 prevent dust from 6

off

I

follows

models

i

2

of installation

shown in Figure EF 35

j

position

Connect air

5

fornia

right after

hose to air check

12

5 to 9 below connector

fuel level wi th attached

15 to 25 rpm

Run

engine for about 10 minutes at idling speed During this 10 minutes proceed as described in steps

is

level gauge

60 to 70 rpm

recom

temperature

approximalely 7 float position

lOp

p

up

the middle Further

is in

check

ment


or oper load will be good

Make sure that water

rpm

warm

not

ating engine

models and

Manual transmission

2

H

0 283

The top float position can be ad justed by bending float seat Upon completion of the adjust

engine

is 815 rpm

7

Engine speed drops

connection

is

transmission

EF 37

correct

11 Turn the idle adjusting screw clockwise until engine speed drops off below specified rpm

the

Check carburetor pipes for proper

engine

7 and 9 above until

best idle mixture

at

manual

step

Figu re When

described

as

in step 9 can be carried out

CO meter

of gauge

in

idle

670 rpm for automatic transmission models in D position Adjustment

adjustingsqew

L

adjust

mill

in steps 6

If

If

speed

until maximum rpm is

screw

obtained

Connect air

to

idling

at

run

h

position

and needle valve stemis I 3 0 051

to

rals

0 067 in n

3

so

between float seat

Jloa t

to

L7

when Iloat is

goppe

mm

fully re

q

After adjustments in steps I and have been made make sure

2 above

that when fuel is delivered to the float chamber the fuel level is maintained within the range of23 mm 0 91 in shown in FigureEF 38

as

the established

Install idle limiter cap in position sure that the adjusting screw

making

run

can

another

rotate

CO RICH Carbo

to

1 8 turn

in the

direction per

CO

below

rich

rotation 450 lIS

Engine speed Manual transmission CO

815 rpm

t


D

in

position

SQ


sary

adjust

at

1 600

if

cap

Fig EF 36 Setting idle limiter

neces

need not

km

1 000

miles service 9

1dle lim Iter

0 91 in

EF260

At about 10 minutes after

engine

FAST IDLE

cap

I

required by

specifications This operation out

mm

Fig EF 38 Checking ruellevel

ET031

8

be carried

23

J

670 rpm

it to the value

H

lean

With

moved

FUEL LEVEL

valve clearance

1

Turn down float chamber to al low float to come into contact with

placing

needle

cam

valve and

carburetor

from engine

measure

EF 22

Hu shown

screw

the

on

A

assembly

measure

with

upper side

the first step

a

wire gauge

of fast on

reo

throttle

fast

idling idling

Fuel

Engine Fast

idling earn steps

o

04th l

Fast

Choke connecting

1st

rod

Z EC528

Fig EF 39 Mea uring throttle valve clearance

carn

Fast idling screw Choke valve

2nd

EC527

idling

Nut

Throttle valve

Fig EF 40 Fast idling

cam

steps ET033

The clearance should be

2

specified

value in the following table Ifnot ad the

just

idling

clearance

turning fast

by

Fig EF 41 Adjusting the clearance of throttle valve

screw

Clearance

A

mm

in

Fast

idling

1 33 to I 47 0 0524 to 0 0579

MfT

1st 1 58 to 1 72

AfT

3

To check fast

idling

cam

idling cam at 2nd step and read engine speed Fast idling cam is prop erly set if engine speed is within

Set

Fast

Engine speed rpm

idling

specifications

below Clearance

A

in

2nd step is reference value

A

Clearance

earn

18 1

0 94 to

I 900 to 2 800

MfT

step

0 0622 to 0 0677

fast

setting

follows

by engine speed proceed Warm up engine sufficiently as

earn

mm

in

0 0370 to 0 0465

2nd step L16 to I 40 0 0457 to 0 0551

2 200 to 3 200

AfT

CHOKE UNLOADER

VACUUM BREAK I

2

Close choke valve completely Hold choke valve by stretching

rubber

band between

choke

piston

4

out

Under this condition

clearance carburetor 42 EF vacuum

to

between choke

body

specified

B

adjust the

j

valve in

value by

LL

Close choke valve

iXo CK

a

lever and stationary part of carburetor 3 Grip vacuum break rod with

pliers and pull straight

B

S

completely

Hold choke valve by stretching

rubber

band

between

choke

a

piston

lever and stationary part of carburetor 3 Pull throttle lever until full open

r

Under this condition

I

il

and

2

ance

L

J

adjust

body to 2 45 mm 0 096 bending unloader tongue tor

Figure

clear

between choke valve and carbure in

by

bending Note

brake rod EF516

4

2

Choke piston rod Choke spring

5

Diaphragm cover Choke piston lever

3

Choke piston

6

Choke valve

1

Fig EF 42 Adjusting

vacuum

break

Make

that

throttle valve

is mounted opens when carburetor on the vehicle

If throttle valve rails to open un loader becomes inoperative resulr

ing

in poor acceleration after

is started

EF 23

sure

engine

Fuel

Engine

celerator pedaJ to press al choke valve doses properly

heater circuit with function

Do not altach

designated I

test

to those

tester

Refer to

leads of a

other than 43 Ef

figure

engine not running check for continuity between A and B as With

shown in

figure

and

tioning properly If continuity d for disconnected

Check

cover

at

center

position except the choke housing index

of

not exist

connector or

open

tE jL

2

across

volts

c d

3

exists

to

termi that

ensure

terminals

between

4

Check

voltage

when

no

them

If results

is

2

applied

satisfies

not

4

and the

across

above

choke relay is functioning

automatic

if not

properly

does

continuity

t lal

exist between terminals

relay

choke

replace

12

is

reading

volts

zero


Bi metal

check open

faulty automatic choke

Thermostat

3

Groove

4

EF723

cover

Fig EF 46 Checking automatic choke

housing

relay

ET034

Fig EF 44 Bi

relay

y

3

chamber

2

2

1

J

43 EF

If vohmeter reading is

tting metol

Automatic choke heater Measure

I

3

in

check

Thermostat

or

shown in

of

marl s

properly

circuit

of

any

heater circuit is functioning

c d

as

cenleT

check shown

as

and

ontinuity i

bi rnetal

that

44 EF

mark

With engine running at idle check for presence of voltage across A and B

figure

finger

Do not set b metal cover index

Note

heater is func

a

I

2 and

sure

index mark is set at the

Figure

2

If voltmeter

be

0

choke housing index mark

P T e heater circuit

shown in

with

Apply nals

operational

an

choke relay 46 EF

Figure

that

ensure

heck for binding

3

43 Ef

If continuity exists

as

choke valve

Push

test connector

de

fully

Before starting engine

I

Checklna automatic choke

circuit

Make

automatic

CHOKE

Caution

2

Automatic choke

ELECTRIC AUTOMATIC

Replace faulty parts

heater as shown in

spe 4

automatic

Check

source

choke

heater

ified

of

resistance

re

figure is

san ce

choke

47 EF 3 7 to

8 9

ohms

wiring for proper connection

then start engine 5

After warming up the engine

that choke valve is 6

If automatic choke heater

wiring not

see

fully open source

is normal and choke valve does

operate

hi metal

after

warm

up

replace

t er co

F

Automatic

EF261

choke relay

J

Fig EF 47 Automatic choke heater

j

I

Remove

automatic choke

relay

check

2 Auto

the

choke heater relay

If measured value is not within specification replace bi metal

cover N

INTERLOCK OPENING OF

j 1

ignition key

2

Automatic choke relay OFF Engine stop

3

Automatic

4

Function test connector Altema tor

Engine EF710

5

PRIMARY AND SECONDARY THROTnE VALVE

ON choke heateI

start

Figure tie valve EF278

Fig EF 43 Checking oulomalic choke heater circuit with

fu

nc non

led connector

Fig EF 45 Location of automatic choke relay

EF 24

48 EF

opened

shows

SO

primary throt When primary

throtlle valve is opened 50

plate integrated

the

adjust

with throttle valve

in contact with return

plate

at

A

is

Fuel

Engine When throttle valve ther

locking

is

opened fur

detached

is

arm

B C D D

CIRCUIT WITH FUNCTION TEST CONNECTOR

from

secondary throttle arm permitting ondary system to start operation

see

Do not attach test leads of a circuit tester to those other than

Caution

Linkage between primary and see ondary throttles will function properly

designated

if distance between throttle valve and

Menuel trensmlsslon models

inner wall of throttle chamber is 74 mm

291 0

I

in

Adjustment

is

made

by bending

BC D D

@ I

49 EF

Fig

Adjusting dash pot

l

L

If continuity does

Secondary

Connecting

3

Return plate

ary

t 7 4

lever

Visually

I I

I

Jl Roller

prm

switch

accelerating

inspect

2

gasket and replace if necessary

Figure

amber

5

Throttle

6

Throttle valve

c

closed

is

in

replace solencid valve

DASH POT

by

of the

one

methods with

housing

solenoid valve

than

more

circuit is

MPH

16 km h

functioning

a

10

prop

erly If voltmeter reading is not 0 volt

unit

a

Chassis dynamometer test If voltmeter reading is 0 volt at

check for disconnected connector

Idling speed of engine well

engine sufficiently

and mix a

tuned

up

and

warm

read engine speed when dash pot just touches stopper lever 3

Adjust position of dash pot by turning nut until engine speed is in the

Tightening torque kg

b

Turn throttle valve by hand and

specified

of voltage

a speed of more 10 MPH Refer to

up rear axle

speed of

Notes

2

detecting

stand

engine good condition as

or

at

this test

two

2

striking

and

EF 50

If engine does not stop when igni tion switch is turned off this indicates a

speed

presence

and B

I Raising

If harness

be

A

ANTI DIESELING SOLENOID VALVE

is shutting off supply offuel to

must

for

than 16 km h

that

ture

Check

Conduct

Adjust plate

exist check


pump cover for any sign of fuel leaks 2 If fuel leaks are found check

across

not

connector

amplifier or

following

Fig EF 48 Adjusting interlock opening

1

disconnected

faulty

ACCELERATING PUMP

CAl

is

below

1 4

circuit

functioning properly if continuity exists and volt meter reading is 0 volt d c in step 2

for

1

Check for continuity between A

and B when vehicle is brought to a complete stop Refer to Figure EF 50

connecting link

2

Refer to Figure EF 50

m

After

18

is

to

3 5

13 to 25 ft Ib

replacement

check to be

leaking

sure

and that

star

dieseling anti

sol

noid is in good condition

fuse

B C D D

solenoid

faulty valve

amplifier or

speed

detecting switch

engine and

that fuel is not

burned

3

If by above checks faulty part or it should be removed

unit is located

and tested again If necessary replace

range

Specified

engine speed

1

Manual transmission 1 900 to 2 100 rpm

11 P4

Automatic transmission 1 650 to 1 850 rpm

0

8

4

Tighten lock

5

Make

sure

1 2

Ignition Icey

3

Amplifier

4

Speed detecting switch Above 10 mph OFF Below 10 mph ON

5


6

B

nuts

that

engine

drops smoothly from 2 000

to

speed 1 000

l

rpm in about three seconds

Fuse

C D D solenoid valve

EF711

Fig

EF

25

EF 50 Checking B C D D circuit with function test connector for manual transmission

Fuel

Engine AUtomatic trailamlsalon modela I

With inhibitor switch P

or

UN

check for resistance between A and B

3

Refer to

heated to

check for presence of A and B Refer to

position

voltage across Figure EF 51

If ohmmeter reading is 25 ohms below

is

ading

BC D O

If voltmeter

12

circuit

volts

is

above

func

of

ading

solenoid valve

HI

m

IY

3

faulty

switch

idling Idling Adjustmenl

prop

or

oR

it

in

or

D

again If necessary replace

4

Run the engine under

engine

5

vacuum

1

@

increases

idling

Check that the B C D D set pres

Ignition key

sure

is within the

Specified

T switch Inhibit

N P positions ON I 2 D R positions

and

OFF C D D solenoid valve

3

D

4


5

Inhibitor relay

pheric

Generally just the B CD

it

510 to

D

490 to

to

harness

ad

to

adjust

it

a

to

mmHg

20

9 inHg

while

idling

and

en

line b

connecting

Connect

vacuum

rubber

hose

between

gauge and intake manifold as

such

of the

hoost

type is s type mercury type

recommended

a

an

proceed

Remove

set as

the B C D D

given

example

the

of pressu

specified

set

from the

and altitude

pressure location

if an automatic trans

altitude of 1 000

the

manometer should not be used

To properly

56

the set

mission model vehicle is located at

Bourdon

as

FiguEF

find

atmospheric

shown

For response

See

checking

in Figure EF 56 pressu

pipe quick

B

When

B CD D

screw

2

gauge and

vacuum

Fig EF 52 Removing harness of solenoid valve

a

operating

is

pressure

pressure will be

by tracing the arrow line A See Figure EF 56 When alti tude is known operating pressure will be found by tracing the arrow EF262

the

atmospheric

found

tool measure

When

known

the

driver

I

530

Notes olenoid valve

is 3S follows

Tachometer

pressure

7inHg 21


however if it should

Prepare the foUowing

gauge

atmos

550 mmHg

20 1 to

19Tto

1

B C D O

is unnecessary

necessary

A

level

sea

30 inHg

pressu

solenoid valve

BC D D

Note

pressure

m

Controlled

Deceleration Device

A

0

Manual transmission

Fig EF 51 Checking B C D D circuit with unction t st connector for automatic transmision D D

specified

pressure

760 mmHg

EF712

2

then

600 abruptly to 23 62 inHg or above and mmHg then graduaUy decreases to the level

2

gine speed

to

At the time the manifold p ssure

6

I

load

throttle

set at

procedure

no

3 000

to

valve

yu

become

speed

quickly close

3 500 rpm

@

of Boost

position

650 rpm

moved

Increase

To B

EF 21

750 rpm

position

Set pressure

in page


faulty part

should be

is

Manual transmission

inhibitor relay

or

it

Idling engine speed

B C D D sole

If by above checks

and tested

OFF

faulty

until

engine

operating temperature adjust the engine at nunnal Refer to the item setting

is 32 ohms or for poor connection

connec or

unit is located

inhibitor switch

inhibitor

2

functioning

Warm up the Then

or

reading

check

noid valve

is zero check


With

circuit is

If ohmmeter

tioning properly

2

EF 51

Figure

erly

If voltmeter dc

ON

specified

BC D D

is

m

set

3 280 ft ssu

p

445 mmHg

for 17 5

inHg

set

follows

the harness of solenoid

valve

7

If it is higher than the set level

turn the

Fig EF 53 Connecting

EF 26

vacuum

gauge

correct

adjusting adjustment

screw or

is made

nut until

Engine Non California models

Adjusting

Note

Counterclockwise

models

turn

for

In this

adjusting

labored

with lock spring in

place Always spring prop erly to prevent changes in set pres

nut

40

sure

models 1

8

Race

the

engine

and

check for

If it is

turn the

1

Adjusting Cover

screw

50 MPH

CD

s

e ET037

California models

or

the accelerator

lower than the set level

adjusting

screw

or

vehicle

nut until

When the engine speed does

not

must

2

or

in top gear in

be

chassis

pedal

decelerate

manual

0 position auto and then releasing and

After

letting

sure

is at the

the

doing this

check whether the B C O D

adjustment is made Race the engine and check for 10 adjustment If engine speed cannot be decreased to idling when checking B C D D set pressure proceed as follows correct

2

10

matic transmission

adjustment 9

engine

road test

I

transmission

2

the

case

by

dynamometer or 3 by raising up rear suspension member on a stand accel erating the vehicle to 64 to 80 km h

set lock

Clockwise California Non

B C D D

adjusting

in or out

nut

California models

Adjusting

When

California

screw

Fuel

set pres

predetermined

value

or

not

fall

idling speed it is necessary to reduce the negative idling pressure of to

t

1 2

the

manifold

to

lower than the set

pressure of the B C D O

Adjusting nut Lock spring

EC692

Fig EF 54 Adjusting

et

pressure

speed

will

when

the

The engine drop to idling speed negative idling pressure is

higher Ihan

not

the

sel

pressure

of the

B CO O

vacuum gauge

acuum

gauge

Vacuum gauge

Intake

gjl 11 Road

test

M Intakema

V 9iI 21 Chas

amomeler

3

iY n

Raise up rear axle

housing by

stand ET133

Fig EF 55 Testing sel

EF 27

ure of the B C D D pre

300

n o

1

000

2 000

3

000

4

000

5

6 000

000

ft Altitude

0 5

o

10

1 5

2

0

km EF558

Fig EF 56 Changes in set pres ure versus changes in atmospheric pressure and altitude

B C D D valve

3

solenoid

4 I

Turn

on

engine key

Do not start

a

dick is heard

I f a dick is not heard ar all

discontinuity

Ensure that solenoid valve clicks

intermittently

shown in

solenoid valve

Figure

electrified

check

for continuity with a circuit tester

engine when

If

is normal

is detected

If

replace sole

noid valve

as

Amplifier

EF 57

Manual

transmIssIon models The amplifier is installed EF262

Fig EF 57 Checking solenoid valve

EF 28

at

the rear

ofthe speedometer To check proceed as follows

Fuel

Engine I

Set circuit IA min

range

probes of

in d

tester

fuU scale

tester

c

ampere

connect test

shown in Figure

as

Ensure that

when

tester

ignition key

pointer deflects

is turned

If tester pointer does

4

Do not confuse

negative

positive line with

properly amplifier

line

Turn

circuits

ing switch

ignition key

ON

to

is

b

not

Counties

1 219

above

more

on

when solenoid valve and

EF 58

2

3

deflect

designated by

detect

Counties

speed functioning faulty

m

sea

law

4 000 ft

level as

or

have been

High

Altitude

For further details refer

to 1977 DATSUN PICK UP Service

are

BuUetin Pub No 257

posi

tion

I

v

t Q0 1 EF733 EF264

Fig EF 61 Checking altitude compensator

1

Ignition key Amplifier 3 Speed detecting 2 4

switch


Fig EF 58 Checking amplifier If results satisfy

Inhibitor switch

bitor


not

relay

replace

is

oJ

at all

for the

particular engine designed By com pletely disassembling which will allow deaning of all parts and passages the carburetor can be maintained its origi

l 4

carburetor

perfectly adjusted

speeds

for which it

was

condition

and will continue to

deliver the proper ratios To

L

maintain

of passages and EF287

Fig EF 60 Checking inhibitor relay ALTITUDE COMPENSATOR

California models Make

The

delivers the proper fuel and air ratios

nal

11

44

OPERATION

if

@

I jj

models

inhi

functioning properly relay

it


above

inhibitor

Refer to the AT section

Inhibitor relay

the

MAJOR SERVICE

accurate

carburetion

discharge

holes

treme care must be taken in

Use

ex

cleaning

only carburetor solvent and

compressed air to clean all passages and discharge holes Never use wire or other pointed instrument to clean or carburetor calibration will be affected

that altitude com pensator to carburetor hoses are con sure

nected properly and that they Inhibitor

relay EF724

Fig EF 59 Location of inhibitor relay 2

Make an inhibitor

Apply 12 volts

that

c d

ensure

across

termi

that continuity

continuity does

not

exist between terminals 2 and 3 when no

voltage

is

is

applied

across

them

not

REMOVAL Remove

Check that altitude compensator

properly set At low altitudes

as

exists between terminals 2 and 3 Check

2

At high altitudes

60 EF

shown in Figure nals 1 and 4 to

relay check

are

cracked and obstructed

Close

Open

taking sufficient

a

properly adjusted when the position of the H L lever is changed

disconnecting fuel lines spill fuel from fuel pipe

do

b When removing carburetor do not drop any nut or bolt into intake manifold

should be

EF 29

engine

the following

When not

The idle Pm and CO vary accord ing to the altitude Therefore they

care to

Precautions

Notes a

carburetor from

c

Be careful not to bend any

part

or

scratch

Engine

Fuel

DISASSEMBLY AND ASSEMBLY A B

C

Choke chamber Center body Throttle chamber

ff

oI C

f

Q @

J ID tJ @

1

Lock lever

11

2

Filter set

12

screw

3

Fuel filter

13

Accelerating

4

Fuel

14

Throttle return spring

5

Needle valve

6

Needle valve

7

Fuel chamber

8

Accelerating pump parts Altitude compensator pipe California models

9

nipple

tng

ail

body

parts

bleed adJ

@

15

Accelerating Automatic

17

Automatic choke body and

cover

diaphragm chamber Richer jet 19 Coasting air bleed I 20 Primary main jet 21 Secondary main jet 22 Secondary slow air bleed 23 Secondary slow jet 24 Plug 18

Air

bleed

Coasting jet 27 Secondary main

@

air

bleed

28

Power valve

29

Primary main air bleed Plug Primary slow jet No 2 primary slow air bleed Primary and secondary small

30 31 32 33

venturi

34 35

Venturi stopper screw Choke connecting rod dieseling Anti

36

J

pump rod

choke

26

@1

I

pump lever

16

25

@

High speed enricher air bleed Choke valve

solenoid valve

37

Fast

38

Diaphragm chamber parts

39

Idle

limiter cap

40

Idle

adjust

41

Idle adjust screw spring

42

Throttle adjust

3 44

idle

cam

screw

screw

5Crew Thr9ttle spring dj t Primary and secondary throttle

valve 45

B C D D

46

California models Vacuum control solenoid valve

47

B C D D

Califomia Non

models

Note

Do not remove the parts marked with an asterisk

Ill @

EF725

@ff

Fig EF 62 Carburetor part EF30

Engine Disassembly Properly screwdrivers

nozzles

screws

wrenches

filling be

must

and jets

as

used

well

as

and

and nuts

ex ercised not

on

the

2

on

the

beiore

to

Fuel

and

damage

care

must

be

any parts

Clean the carburetor

thorougWy

disassembly

3

Do not attempt to remove any parts marked with an asterisk CO in

Figures

EF 62

EF 63

EF 64 and

EF 66

Choke chamber parts

1 2

Coasting air bleed adjusting screw High speed enricher air bleed

3

Choke valve

6

ing pump lever spring Accelerating pump rod

7

Automatic choke

8

Richer jet Automatic choke body and

4

AcceJera

5

Throttle return

9 10

cover

diaphragm chamber Coasting air bleed

@ Note

Do not

remove

the parts

marked with an asterisk

fi

I

1i

8

J

l EF 225

Fig EF 63 Removing choke chamber parts

EF 31

Engine

Fuel Vacuum control solenoid

Center

body parts

valve

Sets

2

B CD

3

Coasting jet

4

Secondary slow jet

5

ptug

6

Air bleed

1

Secondary slow air bleed Secondary main air bleed

8 9 10 11 12

13 14 15 16

1

D

Power valve

Primary main air bleed Weight and outlet valve ptug Primary slow jet slow air bleed Ptirnar Accelerator pump assembly AntkUeselingsolenoid vain

17

Fast idle earn

18 19

Choke connecting rod Fast idle earn shaft

20

Ventuci stopper

21

Primary

and

screw

secondary

small venturi

@

l

Note

Do not remove the parts

marked with

an

asterisk

It EF726

Fig EF 64 Removing jets Float

i

i

j

L

1

V

4 2

Ji

@

c

@

4 S

JlJ

I

4 6

11

e4

Qll1D

Yr

i

lil

c u

1

p

if

1 @5 I

1

Secondary main jet

CJi

2

Primary main jet

3

to1

4

r

r

U I

1 tt

J

1

7

4

1

Float chamber parts Fuel inlet assembly Lock lever

4

2

Filter set

4

3

Fuel f1Iter

44

Fuel nipple

45

Needle valve body Needle valve

Hi 5

lv 8rtj

screw

Diaphragm chamber aiSembly EF227

Fig

EF 32

EF 65 Removing float

Engine

Fuel

Throttle chamber parts

I

Idle

2

Idle

3

Idle

limiter cap

5

adjust screw adjust screw sprinl Throttle adjust screw Throttle adjust screw sprini

6

Primary and secondary

4

throttle valves 7

Nut

Notc

Do not

remove

marked with

an

@ff

the parlS

asterisk

EF827

Fig EF 66 Removing throttle chamlHr parta

Assembly To

assemble

bly procedcre following I

Thoroughly

reverse

the disassem

taking

care

wash

all

to

the

the

parts

Inspect gaskets

to

see

if

they

or

if edges

are

If any of such undesirable condi tions is noted they must be replaced Install jet and air bleed having the same size number as that of original 3

before assembling 2

appear hard or brittle torn or distorted

EF 33

one

4

After

reassembling

carburetor

check each rotating portion or sliding portion for smooth operation

Engine

wuler

gum

or

l

arbon

taminatiun in or on exterior

parts of

arburctor

a

sihk for

reason

dcpends

upon

inspection I

Blow

with

con

moving

often respon

arc

unsatisfactory performance

For this

efficient carbutetioll careful

while

all

and

cleaning

servicing and

castings

air and blow off all

parts until dry Do not

seriously affect carburetor calibrs lion 2

Check all parts for

is noted

placed

wear

damaged parts

Note

especially

Check throule and choke shaft

bores in throtlle chamber and choice of roundness out chamber for wear or

Inspect idle adjusting needle for Such a condition re or ridges

3 burrs

quires replacemen 1 Inspect gaskets

0

see

if they

or briUle or if edges are appear hard torn or distorted If any such condi

must

If

wear

be

re

the following

4

noted they must be replaced Check filter screen for dirt or lint

Clean remain 5

and if

screen

is

distorted

linkage

for

rod

of

Jets Carburetor

jet

performance depends That is why

and air bleed

be fabricated

these components

must

with utmost care

To clean them

use

solvent and blow air on them

cleaning Larger inner jet

numbers

tamped

larger

diameters

indicate

on

the

Ac

cordingly main and slow jets with lalger nUmbers provide richer mixture

operating

the smaller the numbers the leaner the

Conversely the main and through which air to make the fueLleaner if through passes they bear larger numbers the smaller

condition

mixture

6

Inspect operation of accelerating pump Pour f el into jloat chamber

slow air bleeds

and make throtlle lever operate Check condition of fuel injection from the

the numbers the richer the fuel

EF 34

dia

phragm chamber and block passage of vacuum with finger When connecting rod becomes free check for leakage of air or damage to diaphragm

or

plugged replace

Check

accelerating nowe 7 Push connecting

on

tion i

pass drills or wires calibrated through jet or passaaa as this may enlarge orirlce and

Note

assembly

must

replaced

2

3

passages

compressed

If wear is noted

wear

be

Dirt

Check float needle and seat for

I

CLEANING AND INSPECTION

Fuel

Engine Fuel SERVICE DATA AND SPECIFICATIONS

California Nl n

modell

I

Manual transmiSsion

California modeb


I

Manual transmission


Airclelllcr Ail control val

fuUy opens

Idle ompensatoI

partially opens

Hi mettiNo metal Bi

Oc oF oCeF oCeF

partially opem

ntrol valve

Air

86

above 55

129

to

30

to

54

86 to 129

above 55 131

131

l

60

to

70 140

to

158

60 to 70 140

to

158

No 2

70

to

90

to

194

70 to 90 158

to

194

158

Oc OF

tor fully opens ompen

Idle

30 to 54

No 1

above 70

158

above 70

158

Hi metd No 2

above 90

194

above 90

194

metal Bi

Fuels Stem

kpJcm2

Fuel prtuure Fuel pump C rbu

US

apacHy

pt min

at

0 21

poi

0 27

to

t OOO

rpm

2 99

3 84

to

0 21

0 27

to

i I OOO 2

to

2 99

i 2

1 000

3 84

I OOO

tor

C rbu

tor

Stromt rg type

Strombcra type

type

Carburetor model

OCH340

rom

Venturi diameter

48A DCH340

Secondary

Primary Outlet diameter

7A

in

30

I8t

340 339

in mm

24

0 945

310 220

Main jet

199

Main air bleed Slowjet

Secondary

Primary 1 181 30 24

199

170

160

148

1100

Float level U

mm

fuel preuure

kg cm2 psi

23

in

Secondary

30

181 1

34 1 339

31 1 220

24

0 945

31

1101

170

160

170

148

1100

148

1 30 24

0 945

60

1339

31

101

1220

1160

170

1100

60 1

148

180 140

0 906

23

0 17 2 40B

Secondary 34

181

140

23 0 906

2 408

1220

Primary

1160

143

0 906

0 17

Primary

46A DCH340

1339

1160

143

Power val

34

0 945

1160

45B DCH34Q

23

0 17 2 408

0 906

0 17 2 408

Adjustment Engine idling Ignition timingIdle speed mloro Fuel level

CO at

1201750 rpm

2 1

120 650 rpm position CO

0

750rpm 100

t 1 2

t 1 C02

120

650 rpm

0

position CO

t 2

1

adjustment

Gap between

Ive

at

and noat

stem

mm

in

H

7 2 0 283

7 2

0 283

7 2 0 283

7 2 0 283

H

23

23

0 906

23 0 906

23

h

Fast idle

CO

adjwtmcnt Fast idle

Gap between throttle

earn

0 906

1 3 to

13

to

17

0 051

to

0 067

0 051

13

to

17

to

0 067

133

to

147

0 0524

to

0 0579

17

to

0

to

172

to

0 0677

0 051

067

0 906

13

to

17

0 051

to

0 067

158

to

172

0 0622

to

0 0677

tint step

IYe and carburetor

33 1

body

0 0524

in mm

to

147

to

0 0579

158 0 0622

Vacuum break

adjustment Gap between choke alve and carburetor body

142

0 056

1 42 0 056

142 0 056

1 5 0 059

2 45

0 096

2 45 0 096

24

2 45

in

mm

Choke unloadel

adjusttncnt Gap between choke alw and carburetor body rom

0 096

0 096

in

Bi metalsettinl metal Bi

resistance

at

2Ioe 700F

3 7

n

to

lnterloc k opcnina of

primary and secondary

throtUc valves Duh pot

adjustment without

diclClinasolenoid Anti

cD D a

30 inlla RC D D

3 7

89

8 9

to

3 7

Center of the ndex mark

metalsettina Bi

C valV

set

p

JSure

0

m

loadin

tiahtenina torque ka

sea

7 38

Im

900 1

m

lb in

180

to

level and 760

atmospheric pressure J tiahteninl torque

mmOn

mmHg mmHa inHg kg m n b

20

to

7 38

0 291

to

650 1

2 100

350 156

to

304

180

to

510

to

550

490

20 1

to

21 7

19 3

40 17 4

to

34 1

EF 35

20

to

40

3 7 to 8 9

B 9

Center of the index mark

0

to

350

to

291

7 38

0

850 1

1 900

to

to to

11

490

to

530

21 7

19 3

to

20 9

to

20 1

to

20

to

to

40

17 4

to

to

304

34 7

180

1 850

550

510

20 9 34 7

180

to

291

156

530

4 to

304

0

350

156

to

1 650

2 100

350

156

7 38

290

to

20 to 40

17 4

to

to

304

34 1

Engine

toms and causes of carburetor troubles

TROUBLE

and

DIAGNOSES AND CORRECTIONS

remedies for them

Condition

Overflow

Excessive fuel

consumption

are

listed

appears to have some problems when actually the electric system is at fault

to

facilitate quick repairs There

are

the

syml

Probable

that

Therefore whenever the engine is mal

various causes of

malfunctions In the following table

Fuel

It

sometimes

carburetor which has

a

engine happens

no

functioning

fault

ing carburetor

Corrective action

cause

Dirt accumulated

on

needle valve

Clean needle valve

Fuel pump pressure too high

Repair

Needle valve

Re place

improperly

seated

Fuel overflow on

each main jet

Clean

Choke valve does not open valve

seat

overflow

Replace

Main air bleed clogged

Outlet

pump

See condition

Slow jet too large

the

fully

Adjust

of accelerator

pump

Lap

improper Linked opening of opens too

Power shortage

secondary

throttle valve

Clean

Every throttle valve does

not

open fully

Adjust

Idling adjustment incorrect tr

Improper idling

AdjusL

clogged

FIICI Vacuum jet Air c1eane

Adjust

early

Main jets clogged

ir pa

clogged

Clean

clogged

Clean

Diaphragm damaged

Replace

Power valve operating improperly

Adjust

Altitude compensator setting incorrect Cali fornia models

Correct H L lever position

Slow jet clogged

Clean

Every

throttle valve does not close

Secondary properly

throttle

Throttle valve shafts

valve

adjustment

Overhaul and clean

Replace carburetor

fauJiy

tightening improper

Fuel overflow BC D D

im

worn

Packing between manifold

Manifold carburetor

Adjust

operating

Replace packing Correct See

incorrect

Vacuum control solenoid

l

Stuck anti stall dash pot

Replace Replace

EF 36

tightening

ondition

Adjust

damaged

electrical

should be checked rust

rl1ow

ov

system

before adjust

Engine

Condition

Engine hesitation

Probable Main jet

or

Fuel

Corrective action

cause

Clean

slow jet clogged

By pass hole idle passage dogged

Clean tube

Emulsion tube

Clean

dogged

Idling adjustment Secondary

Adjust

incorrect

throttle

valve

operating

im

Overhaul and clean

properly Altitude compensator setting incorrect

Cali

Correct H L lever position

fornia models

Engine start

does

not

Fuel overflows

See condition

No fuel

Check pump fuel pipe and needle valve

Idling adjustment incorrect

Adjust

Fast idle

adjustment

Damaged

dieseling anti

incorrect

solenoid

EF 37

Adjust Replace

overflow

SECTION EC

DATSUN PICK UP MODEL

620 SERIES

I NISSANI NISSAN MOTOR CO TOKYO

LTD JAPAN

EMISSION CONTROL SYSTEM

2

GENERAl DESCRIPTION

EC

CRANKCASE EMISSION CONTROL SYSTEM

EC 2

EXHAUST EMISSION CONTROL SySTEM

EC 3

EVAPORATIVE EMISSION CONTROL SYSTEM

EC 30


EC 32

Emission Control

System

of

GENERAL DESCRIPTION There

are

system These J Closed

three types of control

2

Exhaust emission control system

are

3

lhsion ell

type

CIllnkcase

Evaporative

control

sys

sions to

tem

emission

Pericxiic

control system

seCV1Clng of these systems should be carried out to reduce harmful emis

and

inspection

a

minimum

required

CRANKCASE EMISSION CONTROL SYSTEM INSPECTION

DESCRIPTION This system

returns

The

blow by gas

p

blow by

er cover

gas

through

into the crankcase

draw

blow by flow

the

insufficient

tluough

the to

the

and its flow goes through the tube connection in the reverse diree

valve

the P C V

tion

On vehicles with

valve

Normally the capacity of

is

blow by

the valve

some

through the

is sufficient to handle any blow by and a small amount of ventilating air

retor

an

excessively high

of the

P cV VALVE AND FILTER

con

air cleaner to rock

vacuwn

the intake manifold sucks

by

tube

Under full tluottle condition

During partial throttle operation of blow

the

manifold

gas to the intake

manifold

the

is then drawn

tluough

necting carburetor

The positive crankcase ventilation C V valve is provided to conduct

the engine

cleaner

air

air cleaner

crankcase

air

from the dust side of the cadlUretor

to

both the intake manifold and carbure tor

ventilating

flow will go

tube connection to carbu

air cleaner under all conditions

Checking P C ance

V

valve

following

with the

in accord

method

With engine running at idle remove the ventilator hose from P C V valve if the valve is working will be heard

as

a

air passes

hissing noise through the

valve

and a strong vacuwn should immediately when a fmger placed over valve inlet felt

Replace

be is

P C V valve and filter in

accordance

with

the

maintenance

schedule

4 VENTILATION HOSE 1

Check

2

Disconnect

If any

and rocker

II tll

TIL

1j GUuuu

2

Sealtypc oil level gauge Bame plate

3

Flame arrester

1

4

Filler

5

P C Y valve

6

Steel net

7

Bame plate EC716

EC l

connec

all

hoses

and clean

cannot

be

free

of

replace

Ensure that flame arrester is surely inserted in hose between air cleaner

If

Fig

hose

obstructions

1

Blow by gas

hose

with compressed air

Lkf c Fresh air

and

hoses

tions for leaks

01

c

Crankcase

miaion control ay tem

EC 2

cover

Emission Control

System

EXHAUST EMISSION CONTROL SYSTEM CONTENTS EC

DESCRIPTION EARLY

FUEL EVAPORATIVE

CONTROL SYSTEM

EC 19

DESCRIPTION

DESCRIPTION

EC

6

OPERATION

OPERATION

EC

6

EC

7

EC

7

EC

7

DESCRIPTION

EC 26

EC

7

OPERATION

EC 26

INSTALLATION

INSPECTION SPARK TIMING

CONTROL SYSTEM

DESCRIPTION

EC 19


EC 23

INSPECTION

EC 24

CATALYTIC

EC 26

CONVERTER

REMOVAL

SPARK DELAY VALVE

AND INSPECTION

EC 27 EC 27

EC

7

EC

8

FLOOR TEMPERATURE WARNING

EC

8

SYSTEM

DESCRIPTION

EC

8

OPERATION

EC12

OPERATION


EC 14

REMOVAL


EC 14

INSTALLATION

EC 29

INSPECTION

EC 17

INSPECTION

EC 29

Automatic transmissiom models only INSPECTION AIR

INJECTION SYSTEM

DESCRIPTION The

exhaust emission control sys

tem is made up of the

3

EC 19

6

REMOVAL AND

2

E G R

EC

E F E

I

GAS RECIRCULATION

EXHAUST

3

SYSTEM

following

Early fuel evaporative system Spark timing control system Air injection system A IS

4

5

INSTALLATION

EC 27

DESCRIPTION

Exhaust gas recirculation control system

Catalytic

EC 27

converter

E GR

EC 28 EC 28

7

Altitude compensator

California

models California

models 6 Boost controlled

As regards the last two units refer

deceleration de to

vice B C D D

3 EC

the

Engine

Fuel section

Emission Control

System

IV

7

ID

9

I

Thermal

2

Check valve

3

Air

4

Auto

vacuum

valve

gallery pipe

6

choke canet Automatic temperature control air c Anti Backfire valve A B valve

7

Boost

5

Controlled

Deceleration Device P

10

E

11

Air pump air cleaner Carbon canister

12 t3 14

8C D D

C V valve Air relief valve

8 9

G R control valve

Air

pump ET365

Spark delay valve AfT models

models Fig EC 2 Exhaust emission control system Non California

4 EC

Emission Control

System

5

7

@

@

1

2 3 4

5 6 1

Thermal acuurn valve Check valve

If

Altitude compcnlator in air cleaner Air gallery pipe choke AutQ Automatic temperature control air cleaner

8

Anti 8ackfue valve A B valve Boost Controlled Deceleration

9

P C V valve

DeVice B C D D 10

Air relief valve

II 12

E G R control valve B C D D control valve and solenoid valve

13


14 16

Air pump air cleaner Carbon canister Air control yai e

17

Air pump

15

ET368

Fig EC 3 E hau EG S

t

emilsion controlay tem

California mod

ls

Emission Control

EARLY FUEL EVAPORATIVE SYSTEM E F E

valve shaft is wtalled

DESCRIPTION

manifold through

4 EC

trol

Construction of the early fuel evap system is shown in Figure

orative

rI

A control

valve

valve

is

The

System

valve welded on

This

bushing

called

Heat

heat control

spring and counterweight which are assembled on the valve shaft projecting

the

the

to

con

rear

manifold

control

valve is

luated by the coil spring

1

to

the exhaust

cured to

ac

and snap

thermostat

of the exhaust

outside

The

counterweight is se the valve shaft with key bolt ring

@

rW

1

Intake

2

Stove

9

manifold

gasket

Sc

w

10

Thennostat

11

spring

4

Heat shield plate

12

Coil spriiig Control valve shaft

5

Snap ring Counterweight Key Stoppel pin

13

Heat control valve

14 15

Bushing Cap

16

Exhaust manifold

ManifoktstOve

6 7 g

EC532

Fig

The early fuel evaporative system is provided with a chamber above a

is

manifold stove moonted between the

exhaust gas heats the manifold stove

intake and exhaust manifolds During engine warming up air fuel mixture in

control

changed

the solid

in direction

lines in

close Open

Figure

operation

valve

is

as

shown by 4 The EC

of the

controlled

heat the

the carburetor is heated in the cham

by counterweight and thermostat spring

bet by exhaust gases

which is sensitive

This results in

improved evaporation of atomized fuel droplets in the mixture and in smaller content of exhaust gas

hydrocarbons He in the especially in cold weather

operation The

exhaust

gas flow from the engine is obstructed by the heat con trol valve in the exhaust manifold and

to the ambient tem perature around the exhaust manifold

4 Early Fuel EC

With this condition

The counterweight rotates counter

tem

E FE

the heat control

valve is in the

fully closed position obstructing the flow of exhaust gas As engine tempera lure goes up and the ambient temperature becomes high enough to actuate the thermostat spring the counterweight begins to rotate clockwise and again comes into con tact with the stopper pin With this condition

OPERATION

Evaporutive

the heat control valve is in

the full open position and exhaust gas passes through the exhaust manifold as

clockwise and stops at the stopper pin mounted on the exhaust manifold

shown by the dotted lines in Figure 4 without heati ng the manifold EC

while the engine

stove

temperature is low

6 EC

Emission Control System stopped

visually

check E F E system for the

following

2

REMOVAL AND INSTAUATION

With

engine

items

spring for dismount

Thermostat

1 ing

Stopper pin for bend and count er weight stop position for dislocation 2

3

control

heat

Check

valve

for

malfunction due to break of key that locates counterweight

to

valve shaft

Check axial clearance between

4

heat control valve and exhaust mani 1

Snap ring

2

Lock bolt

3

6

Key Counterweight Thermostat spring Coil spring

7

Heat control valve

8

Valve shaft

9 10

Stove gasket Manifold stove

11

Heat

4 5

EC533

fold

shield plate

mm

is 0 7

Correct clearance

to 1 5

0 028 to 0 059 in

5 Check welded portion of heat control valve and valve shaft for any indication ofcrack or flaking 6

by

Rotate heat

control valve shaft

and

check for binding

a

finger

between shaft and bushing in closing and opening operation of heat control valve If any binding is felt in rotating

Fig EC

5

Exploded view of E F E

stem

valve

move

operation

shaft in the

rotation direction several times If this

ring D and lock bolt and the following parts can be

Remove snap

@

detached

valve

control

heat

from

position described in 1 1 above and stops again coming into con tact with stopper pin

shaft

Key 00 Counterweight @ spring lostat TherI Coil Note

CID

shaft

not

correct

shaft and bushing and exhaust mani fold should be replaced as an assem

1 is

CHECKING SPARK TIMING CONTROL SYSTEM

heat

welded to valve

at exhaust manifold

@

it is due to seizure between

j

descnoed

previously

control valv

does

condition

bly

spring @ As

binding

operation

and

cannot be disassembled install

To

reverse

2

Counterweight S topper pin

3

Heat

1

INSPECTION

control valve

Run

engine and visually check counterweight to see if it operates

properly For 1 engine turns

Fig EC 6 Operation of counterweight when engine is cold

serves um

in cold

after

counterclockwise until it

and ambient

NOx emissions installed

non

on

transmission

automatic

SPARK DELAY VALVE Automatic transmission

moves

models only

as

2 When engine speed is increased discharge pressure of exhaust gases causes counterweight to move down

ward clockwise con

is

system

models

This

around exhaust manifold

trol valve is in the

counterweight open position moves further clockwise exceeding the

full

advance under varying travelling so as to reduce HC and

comes

engine warms up temperature goes higher

When heat

system

pin installed

gradually

Counterweight down clockwise

control

tirnin

conditions

California

exhaust manifold

3

spark

to control the distributor vacu

This time

starling weather counterweight

some

into contact with stopper to

DESCRIPTION The

cedure

I

EC246

the removal pro

delays vacuum spark during rapid acceleration it

valve

advance EC246 1 2

Counterweight Stopper pin

3

Heat control

valve

Fig EC 7 Operation of counterw ight when ngine is hot

EC 7

also cuts off the

immediately valve is

vacuwn

spark

advance

upon deceleration

designed

for

one

The

way opera

tion and consists of a one way umbrel

la

valve

restrictor

and

sinlered

steel

fluidic

System

Emission Control

I

C bur tor

Distributor side

1

2

EC219

umbrella valve

way One

Fig EC 11 Checking spark

Sintered metal disc

d

tay valve

EC284

Fig EC 8 Spark delay valve

Note or

installing

When that

this

valve

oriented

ensure

Tlus valve

properly replaced periodically

it

shuuld be

Refer

Maintenance Schedule

to

Note

is in

port

If

ance

a

finger

is

greater

than that

Figur ET lO

considerable air flow resist

is fell at port on distributor side

in step 2 above and if the condition of

spark delay valve port horn distributor

when

distributor side

on

the other side See

3

DisInDutor sideBrown

over

air flow resistance is on

Carburetor sideBlack

good condition if

placed

To carburetor

on

Be careful to avoid entry of oil dirt into valve

is

questionable

carburetor side

into

a

dip cup

filled with water Blow air through the other port Small air bubbles should appear

AIR INJECTION SYSTEM DESCRIPTION The Air Injection System A LS is aeSigiieino iiiject coinpressed air sec air corning from the air pump into the exhaust manifold to reduce

ODllary

ribUI0

TOdi

hydrocarbons and carbon monoxide in combustion re exhaust lris through

carburClor

lCiJr

EC

There

type is mounted and

Fig EC 9 Operation 01 park delay Carburetor side Distributor side

on

sists of

an

non

valve and

through

then through the other port distributor side Spark delay valve

EC346

Fig EC IO Checking park delay valve

8 EC

non

A I One S California models

on

non

California

California type

con

air pump air cleaner an air

California

type has in components of the type an air control

to the

California

Remove spark delay valve Blow air

side

other is

The

addition

port on carbure

on

pump a relief valve a check valve an anti backfIre valve an air gallery and hoses

INSPECTION

tor

the

models The

value

2

types of

two

are

an emergency air relief valve These valves prevent ahnonnal tem perature rise of the catalytic converter

Emission Control

System

1

Check valve

2

3

Air gallery pipe Automatic temperature control air cleaner

4

Air

carburetor

hose B

to A

air cleaner

val

5

Anti backfire valve

6

Air hose

A

A B

valve

B valve to intake

manifoW 7

Air hose


to aU hose connector

8

check valve to air hose

Air hose

connector

9 10

3 way connector air hose connector to

Air hose air pump

11

Air hose

12

air cleaner Air pump air cleaner

air pump to air pump

13

Air pump

EC776

Fig EC 12 Non California type A IS

1

Air control

2

Check

3

valve

val Air hose check valve to air hose connector

4

Air

5

Automatic temperature control

gallery pipe

air cleaner 6

Air hose to

7 8


A B

val Anti backfire valve

A B valve Air hose A B valve to intake

manifold 9

Air relief valye

10

Air hose carhuIetor air cleaner to air control valve

11

Air hose

air relief valve to air

hose connector

12

Air hose air hose connector to emergency air

relief valve

13


14 15

Air pump air cleaner Air hose air hose connector to

16

air pump Air hose air pump to air pump air cleaner

17

Air pump

EC777

Fig EC 13 California typo A I S

EC 9

Emission Control Air pump aIr cleaner The air cleaner element is paper

lype

placement

and

The die a

viscous

requires periodic

re

The air pump air cleaner is

bolted to the left front of the hood

ledge

aluminwn

cast

assembly attached engine

is driven

belt A

rotor

System

to

by

pump

air

the

the front of the

an

air pump drive

housing

shaft drive hub inlet and

springs

unit of the pump

type

make up the rotating The rotor located in

the

completes

Each

housing

Carbon shoes

revolu tion of the

EC778

Air pump air c leantr

moved into

pression

a

smaller cavity

Air pump The air pump is

a

a

Leaf springs which

are

the leading side of the shoes

The

rotor

ring

the rotor end

is a steel bolted to

It positions ihe rotor

and holds the carbon shoes

The

vane uses

needle

bearings

All

bearings have been greased

and

There are two typCg of bearing which support the rotor Ball bearing is used for the front one and the

the com

vane

the slots of the

compensate for shoe abrasion

vane

area

After compression

has

vanes

cavities

behind

in every rotor Air is drawn

Air is sealed between the

in

and to seal the rotor interior from the air

into the inlet cavity through a tube connected to the air pump air cleaner Fig EC 14

pumping

support the vanes They are designed to penni t sliding of the vanes

pumping cycle

a

again reaches the

repeat the

rotor

form two

vanes

and to

cycle

ofT center pivot pin and follow the circular shaped pump bore In the two vane

that separates the outlet and

inlet cavity

the center of the pump is driven belt The vanes rotate freely around the

chambers in the

cavity Subsequently it stripper and a section of the

inlet cavities

outlet tubes are visible on the pump exterior A rotor vanes carbon shoes and shoe

outlet

passes the

needle bearing is used for the

passes

rear

two vane type It

positive displacement vanes requires no lubricating seJVice

two

which

i lJ1

I

Jr

l

j 1 2

3

Air pump drive hub HOII ing Rotor ring

spring

7

Shoe

8

Stripper

9 10

Rotor shan

bearing

II

Front

5

Vane

12

6

Carbon shoe

13

4

End

cover

with needle

Ball

j

bearing bearing

Pulley PuDey for air

cover

con

itioner EC560

Fig EC 15

EC IO

Stctionol view ofoir pump

twtrvone type

Emission Control

and injected air which

backfire

I

Tointake manifold

secondary according to engine speed and load condition and prevents ex cessive temperature rise of the cataly air

Construction

is

spring fails

shown

in

Figure

EC 18

air fed from the

of

quantity

causes

the

con troIs

valve

air control

When relief valve

2

burns with the aid of high temperature

CalifornIa models The

and

combustion chambers

the

from

Air control valve

System

pump

tic converter

EC 16

Figure

shown

as

m

applied

coupled

actuate the valve which is

I

manifold

intake

The

pump

in

and air pump discharge pres to the diaphragm chamber

vacuum

F rom

vacuum

construction is

The

sure

c

to

L

AirdisChaJ1le

From air

engine condition

ts

ven

which

the

backflow

occurs

The valve pre

of exhaust

in one of the

gas

following

When

the

air pump

drive

belt

Into axhaust port

The secondary air fed from the air to pump goes through the check valve the air

gallery

where it is distributed to

each exhaust port

The

secondary

air

injected from the air injection nozzle into the exhaust port near the exhaust valve

fails

c

Check valve

is then

cases

1

Fig EC 1B

AIr InJaction

pump discharge lines

To

Secondary air Exhaust gas

valve

Fig EC 11 Anti back ir

A check valve is located in the air

From

Seat

EC292

Check valve

air pump

Rubber valve

3

ECQ69

the

to

Spring

2

cleaner

the diaphragm and control the quanti into the ty of secondary air to be fed exhaust manifold in response

1

I

to mtake manifold

carburetor

air cleaner lr

J

n

EC291

Air control valve

Fig EC 16

Anti backfire valve This valve is con trolled

manifold in the

period

to

vacuum

y

by intake

prevent backfire

exhaust system

L

the ini tial

at

of deceleration

the mixture in the

period

At this intake

manifold becomes

too

ignite

and

combustion

burn

in

the

rich

chamber and burns easily in the

to

ex

air in the

haust system with injected exhaust manifold The anti backfire valve to

intake manifold

the

mixture

air fuel

leaner

provides make

to

and

air r

the

prevents

backfire A schematic

backfire

valve

drawing is

shown

of the in

anti

Figure

V

EC 17

backfire

The anti

nected

to

3

I

Air

2

Exhaust port

3

Air

4

Exhaust manifold

gallery jnjection

nozzle

EC293

valve inlet is con

the air cleaner and the outlet

Fig EC 19

Air injection into exhaust port

to the intake manifold Th

reduces hydrocarbon emission during If the valve does not work

unburned

mixture

Air pump relief valve air pump relief valve controls injection of the secondary air into

The

aeceleration will

be

properly emitted

high speed under a heavily loaded condition It accomplishes the following functions without affecting running

correct function of ItjS valve

the

the exhaust system when the

EG 11

engine

is

at

the effectiveness of the exhaust emis sion control system

Emission Control

Minimizes

gas

tempera

rise

2

Minimizes from

horsepower air injection

losses

re

into

the

exhaust system 3

Protects

pump

excessive

from

back pressure

The air pump relief valve is installed as shown in

The

Figure

secondary

EC 20 air

is

discharged

from the air pump relief valve to the dust side of the carburetor air cleaner

California type The California stand ard type includes a system which

Emargency air retial valve E AR

lure

suiting

exhaust

System

Valve

controls injection of secondary air so as to assure proper function of the

California models The emergency air relief valve con trols the quantity of secondary air fed

catalytic

from the air pump according to load condition and it discharges the see

ary air to

air

into

the

The A

L con

valve

prevent abnormal tempera catalytic converter consists of the following I S

system which allows injection

A

of secondary air into the exhaust port

diaphragm a spring and a which is coupled to diaphragm

sists of

system

a

of second

systems

converter

The emergency air relief valve

supply

tUfe rise in the

atmosphere to prevent overheating of the catalytic

ondary

and

converter

which controls the

a

2

A

ondary valve

bypasses

system which

sec

from the air pump relief the carburetor air cleaner

air

to

during high speed engine operation 3

To carburetor air cleaner

A

system which supplies

air from

Secondary

the carburetor air cleaner to the intake

air

manifold by valve

so as

means

of the anti backfire

to prevent after fire

during

deceleration A system which controls injection of the secondary air by means of the air control valve so as to maintain the 4 1

Diaphragm

2

To carburetor air cleaner

J r

Val

catalytic

3

Spring

4

Diaphragm chamber

erCOndary

optimum temperature level under lightly loaded

EC 21

Califomia type only

mergency air relief valve 5

A

system which controls the sup

ply of secondary air

r

gency

OPERATION

Fig EC 20 Air pump relief valve

two

air

through

the

there

emer

ab

pfevent io

relief vilve

normal temperature rise of the

As mentioned previously EC294

an

at

condi tions

EC536

Fig

converter

cataly

tic converter

are

California type

types of Air Injection Systems a California non type and a

A I S

IS A

only

operation is

as

follows

I

I

t

1

r

9

I

I

0

2

L

3

r

EC179

Air

pump Air pump air deaner Air relief valve

6

Check valve

7

Air gallery pipe Injection non e

8

4

Air cleaner

9

5

Carburetor

10

Exhaust manifold Anti backflIe valve

Fig EC 22 Non California type A IS

EC 12

Emission Control System The

non

follows

California type operates air

secondary

through the air pump the

air

pulley

pump It

as

sucked

is

air cleaner into

by the crank discharged through the air gallety where

driven

is then

the check valve to

To intake

To

manifold

manifold

intake

it is distributed to each exhaust porL

The from

secondary air the injection

exhaust port

near

is

then

nozzle

injected into

Air

the

diSlcharge

to

intake manifold

the exhaust valve

Secondary air

The air relief valve opens only when the discharge pressure of the air pump

spring force of relief valve during high speed surpasses the

tion

EC297

the air

Fig EC 23 Operation of A B

opera

When the air relief valve opens The

the secondary air is discharged in to the carburetor air c1eaner

predetermined tion and

non

manifold

from

California

The

type

includes

air

components of the

type

an

air control

emergency air relief valve

an

air control

valve

opens when

applied to predetermined

the

the

air into the air cleaner

um

cleaner

secondary

When valve

diaphmgm reaches a

level

and

discharges

the pressure becomes low the doses with the spring force of

the

air control

charging

the

valve

and

secondary

stops dis

air

Figure

EC 25 When the intake manifold

vacuum

applied to the diaphragm reaches a E A R valve predetermined level operates to discharge the secondary air into the atmosphere When the pres sure

becomes

spring stops

high

tension

the valve closes

of EA R

discharging

the

valve

secondary

by

and

air

fl

f

I Qj

rn

in

the sum of the air pump discharge pressure and the intake manifold vacu

air to now into the

the

to

valve and

value during decelera

permits fresh

intake

California

addition

The anti backfire valve opens when the intake manifold vacuum reaches a

the

lve

t riu

Jl l 3

I

Air

2

Air pump air

3

Emergency

4

Air

pump cleaner

air

relief valve

relief valve

j I

@

5

Air cleaner

9

6

Check valve

10

7

Air

II

8

gallery pipe Carburetor

12

Air control valve

Injection l Exha

t

nozzle

manifold

Anti backfire valve EC780

Fig EC 13

EC 24

California type

IS A

Emission Control System

o

To intake

jJ

To

manifold

Intake mamfold

lm vaCUl

vacuum

rF r

r

To air cleaner

To air cleaner From air pump Y

9

Gf

9 4

T

From air pump l

h

1

I

I

Actuated

Not actuated

EC299

Fig EC 25 Operation of air control value Notes

REMOVAL AND

Apply engine

a

INSTALLATION

times during Air p

mp sir cleaner

Remove cleaner

air

from

Air cleaner

hoodledge r

EC781

Fig

EC 27 Locotion of E A R wive

Disconnect

vacuum

Unfasten

air

4

Check air

gallery

fractures

or

and nozzle for air

leakage Clean

nozzle with

At time of installation

5

injection

wire brush

a

hold air

to

a

torque of 5 0 to 5 9

kg m

36 to 43 ft lb Check cylinder head air injection nozzle and air gallery for leaks with 6

J

o

damage other

to

3

screw

and

hose

c

t

323 EC

air

hose from anti backfire valve

tt

not

injection nozzle hexagon head with a wrench and tighten air gallery flange

Antl backflravalve

JJ

several

injection nozzle from cylinder head applying engine oil to screwed portion several times

deancr lower

body are built into a unit construction Replace air cleaner clclnen and lower body as an assembly element and Ii

rews

parts

then detach air

hose

atreful

b Be

011 to

above work

Fig EC 26 Replacing oir cleaner

engine running

Check valve

element

Disconnect hose and Air

pum Remove air hoses from air pump Loosen air pump adjusting bar

2

mounting bolts and air pump ing bolts

remove

check

valve from air gallery pipe

mount

then remove air pump drive

Air pump relief vslve Loosen

mounting Air ganery pIpe andinJactlon

air

carburetor sc

ews

and

cleaner

remove

air

order of

reo

pump relief valve

nozzles

bell 3

Remove air pump

4

It is very difficult to

pulley

Remove air pump

from bracket

gallery

from

the

valve

removal of the air gallery pipe and injection nozzles should be under

Disconnect air hoses and

um hose

2

a vacu

from air control valve

Remove

air

con

trol valve from

bracket

taken only when they I

valve

Remove

California modela

vacuum

pipe and

and dismount E A R valve

air hose

are

damaged

Lubricate around the connecting

portion of

air

injection nozzle with oil engine gallery 2

E AR

There

leakage

or

InstallatIon Install in the

reverse

moval

fore

California models l

the air

manifold

without bending the pipe which could result in fractures

Air control

remove

exhaust

Hold air injection nozzle

head with screw

a

and air

hexagon

wrench and unfasten flare

connecting

ait

gallery to injec gallery

tion nozzle Remove air

EC 14

DISASSEMBLY AND ASSEMBLY Disassembly of air 1

and

Remove four remove

pulley

pump

pulley

drive bolts

from hub

Secure air pump drive hub in a EC 28 and vise as shewn in Figure 2

remove

four end

cover

bolts

Emission Control

Note

Never

clamp

on

the aluminum

b

Discard

Always installing

housing

which

screws

moved

System were

re

when

use new ones

8

four

Remove

front bearing tach bearing

securing

screws

cover

place

in

and de

cover

Support the rear end face of air pump housing with Rotor Adapter STl9890000 Drive rotor out by push ing rotor shaft with Bearing Pressing 9

5

Remove

vane

from rotor

Tool STl9940000

STl9940000

Fig EC 28 Removing

4

Remove

Put

end

cover

match marks

0

on

Fig EC 30 Remooing

cover

by carefully tapping around dowel pin with a plas tic mallet and lift up straight

3

6

Remove

two

shoe

needle

nose

four carbon

springs pliers or

from

Note

Carbon

I

I

shoes and rotor

STl9890000

vanes

EC303

Fig EC 32 Removing rotor shaft

using

tweezers

rotor

ring and side of rotor to ensure correct reassembly and remove four screws that retain rotor ring to rotor using a Hexagonal Wrench STl9810000

1Ul

EC661

EC302

A

shoe

0 039 in wider than

is B

I

mm

Do not

confuse them

10 Support the front end face of with housing Bearing Adapter STl9930000 Attach Bearing Driver STl9910000 to front bearing on the inside of air pump housing iuid press out

Notes a

Generally cated

on

match marks both rotor

are

ll

indi

ring and rotor

I

I

by the manufacturer

STl9910000

i

L

9930000

J

1 EC304

Fig EC 33 Remouing ball bearing If replacement necessary ECll1

Fig EC 29 Removing rotor ring

proceed

of front bearing is as

follows

Remove air pump drive hub with standard puller 7

EC 15

11 rder

Keep

disassembled

parts

in


EC562

EC 34 Componenbr of two vane type

Fig Assembl I

Front

of air pump

bearing the

Support

Press drive hub into place with

1 C

preand

until the end face of drive hub touches

end face of air

rear

with a press arid Tool STl9940000

froE

ST 19910000

pump housing with RotOL Adapter STl9890000 Press front bearing into

place

a

Bearing Driver STI 991 0000

c ing in n

c

Bearing Ptessing

j

I

I

ST19920000

STl9940000

STt9910000 EC3Q7

I

Fig EC 36 Pressing rotor shaft

e

L

Notes

X8 03

a

Be

STl9920000 sure

race

Fig EC 35 Pressing ball bearing

to drive front

bearing

Bearing

is installed in

rotor

Torque

four bearing

bolts to 0 1 to 0 2 kg ft lb 3

cover m

securing

0 7 to

is

pump housing

4 1

pump

Support

the

inward

bottom

place

with

a

150 0

mm

2

press 4

touches front

rotor with Rotor Stand STl9920000

bearing

inner race

Air pump drive hub the inward

EC 16

Place air pump drive hub in

a

bottom

Clean

carbon

dust

etc

from

shoe grooves 3 Align rotor with housing proper ly Refer to Figure EC 38 Then insert

and Bearing Drive STl9910000 until the stepped portion of rotor shaft

Support

1

Carbon shoe

vise

00020 to 0 0059 in

rotor with Rotor Stand STl9920000

Press rotor into

housing

0 050 to

of

Fig EC 37 Pressing air pump drive hub

5

Position of rotor end below air

Rotor shaft

EC308

place

that the rotor end pos tioned below the end face of air

cover

r

in

b After ensure

2

inner

of

carbon shoes into directions

place noting

their

Emission Control System Notes a

b

tue u Do not apply an when shaft vane inserting If two

vanes

stress

to

dislocated when

are

shaft correctly

inserting align by inserting dummy shaft Then draw out dummy shaft and vane

vanes

insert c

Note

a

Carbon shoe

A

in wider than

is 1

B

make

0 039

mm

ing

Do not confuse

b If carbon shoes

are

Be

carbon

remove

shoes and clean shoe grooves Reassemble carbon shoes

sure

of

spring

Rotor

ing the

Pack vane bearing 1 melting point grease MIL Esso ANDOK260 insert

dummy

or

with

G 3545 A and

the

Vane

shaft into

face in the wall of

push spring

four

cover

in place

Snugly

the bolt close to the dowel

tighten

Then tighten four bolts to the speci fied torque

0 7 to 0 9 kg

in so that

m

5 1 t06 5 ft4b

ring ring by correctly align

end face of rotor with the

rear

mark in rotor

0

high

equivalent

spring

Tightening torque

to

sure

is

as

cover

spring end face is flush with rotor 8

Vane

shoe

that the outward bend

Install rotor

6

a

shoe groove

exposed beyond

the rotor end face

instaUing

side faces in shoe and that both

ends

them

End

Position end

When

bearing cover

Installing shoe spring Jl

Notes

rear

sembly

EC123

40 EC

replace

necessary

11 EC540

Fig

shaft

when replacement of rear

i 111

Fig EC 38 Install carbon shoe

vane

When wear occurs on vane shaft or

screws

ring and tighten

the specified

to

torque with Hexagonal Wrench ST19810000

Tightening

bearing

torque

5 to 0 7 0

kg

m

3 6 to 5 1 ft lb

STl9900000

EC302

Fig 12

to

5T19810000

2

Install

in

place

on

0 7 to 0 9 kg

m

5 lt06 5 ft lb

as a

EC124

guide

INSPECTION

Fig EC 41 In8talling rotor ring

Note

may require 6 to 16 km 4 to 10 miles wear in running time In the event a slight squeaking

The

80 km h

most

cases

40 to 50 MPH

6 to 16 km

miles will be sufficient for

Shoe spring Place shoe springs in

of shoe

Air InJection

vanes

still remains drive the car about 64

7

bolts

rotor

using Dummy Shaft STl9900000

to

end cover

Tightening torque

EC 39 Vane assembly

vane

ling Insla

Pulley Tighten four pulley securing the specified torque

EC563

Fig

EC 42

4

In

to 10

wear

in

9

Carefuny from

withdraw

groove

dummy

shaft

with

high

air

connections

Retighten

vane

10

or

system hoses for loose cracks

replace

or

deterioration

if necessary

Vane shaft Pack

rear bearing melting point grease

G 3545 A MIL

so

equivalent

ANDOK

260

or

thin coating of grease to shaft and rotor ring and insert

Apply deeper

Check

Removal of dummy shaft

system hosas

shaft into its

bearing EC 17

vane vane

Air

ystem manifold

Check air gaUery nozzles cracks

sary

for

pipe

loose

Retighten

or

and injection and

connections

replace

if

neces

Emission Control

a

reaches

until it

Operate engine

I

and air

if necessary

correct air

before

connec

Check air injection pump belt tension and adjust to specifications if

supply hose

air

control

vacuum

hose from the

California

valve

type

only Insert open pipe end ofAir Pump

Test Gauge to

supply adapter

STl9870000 in

Adapter

Check hose opening for any indi

detected replace check valve Race the engine lightly at about

2 000 cpm

and

idling VisuaDy

then

return

it

to

check the hose for any

indication of exhaust gas leaks before the engine returns to idling speed If leaks

are

detected replace check valve

and

etc

repair

or

correct

if

necessary 3 With engine idling disconnect the outlet side hose of the air control valve and place your hand on the air hose outlet to check for air If no air is felt replace the air control valve 4

Pull

con

vacuum

hose

off from

air

If discharge of air from

trol valve

stops the air con trol valve is normaL Ifdischarge is still felt replace air hose

the valve up the removed vacuum hose

Plug

Clamp hose securely prevent it from blowing

to

stabilize engine running

adapter and test

out Position

air blast emitted

that

check

hose to

Warm up engine thoroughly Before checking air control valve

leaks

4

Disconnect

air

thoroughly hose leading to

Disconnect

3

valve

check all hoses for loose connection

valve from air hose COJUlector

at

check valve

6

functioning properly

cation of exhaust gas leaks Ifleaks are

necessary 4 Disconnect

Air control

C U ornla models

Warm up engine 2

3

air

as

Check valva

checking

injection pump

5

engine

2

for leaks and

gallery

unit is

I

normal operating temperature 2 Inspect all hose hose tions

that the

must be determined

Air pump

System

lliuge so through drilled

pipe plug will be harmlessly dissipated 7

Install

a

With engine

tachometer

speed

pressure produced

serve

at

Air pressure should be 3 94

inHg

on

engine

2 600 rpm ob

at

test gauge 100 mmHg

or more

8

If air pressure above specifications

does

not

proceed

meet as

EC310

fol

Fig EC 43 Checking check valve

lows I

Repeat 2 and

2

Disconnect backfire anti and

ing

3 above

air

supply hose at valve Plug air hose open screw with a clamp Repeat

pressure test 3 With engine speed at 1 500 rpm close hole of test gauge with finger If a leaking sound is heard or leaking air is felt by ftnger at relief valve relief valve is malfunctioning Relief valve should be

replaced or repaired

If air injection pump does not meet minimum requirement of pres 4

sure

test it should be

replaced

Air pump raIle After

valve

completing inspection

of air

check air pump relief valve in

pump the following steps J

Disconnect hoses

valve and

leading

air control

hose connector

to check

valve from air

and install blind cap

to the connector

2

With

EC312

engine

running

3 000 rpm under

no

at

about

load place your

the air outlet of air pump relief valve to check for discharged air hand

on

If no air is felt

replace the

air pump

Emarsancy air rella E AR

2

Control valve

valve

Valve

lCalHornla models L

relief valve

Checking air control valve

45 EC

Fig

Warm up engine thoroughly Before checking air control valve

check all hoses for loose connection The

following procedures are reo commended for checking and or as certaining that the various components

leaks

of the exhaust emission

2 000 rpm under no load Place your hand on air outlet of E A R valve to

con Irol

system operating properly The engine and all components must be at normal operating tempera when

the tests

are

performed diag

Prior to performing any extensive

and repair

necessary 3 Race

are

tures

etc

engine

or

correct

if

approximately

check for presence of discharged air If no air is felt E A R valve is normal EC311

Fig

44 EC

Checking air pump relief

nosis of the exhaust control system it

valve

EC 18

4

Disconnect

B A R valve 46

as

vacuum

hose

from

shown in Figure EC

Emission Control System Race

under

2 000

approximately

no

load

E G R

RECIRCULATION CONTROL SYSTEM

for presence of discharged air If air is felt E A R valve is normaL 5

ing system which indicates

tXHAUST GAS

Place your hand air outlet of E A R valve to check

rpm on

engine

spected

E G R

properly

replace

valve In

system

exhaust

a

returned to

gas recirculation of the exhaust gas is part

the

lower the

pump

I

a

EG R

2

Open

finger engine

place

3

a

Run

under

no

load

at about 3 000

If you feel

R

c1ose operation of the E G R valve

is

controlled

by

the

vacuum

temperature

1 I

D t

Y1

I ID JO

4 0

the outlet

near

then

con

by the E G

quantity

warn

Disconnect hose from air cleaner

and

through

the

to

the E G R

valve which opera tes carburetor vacuum and engine cool

on

VI

thoroughly

is

manifold

thermal vacuum

I

@

valve

trol valve

The exhaust gas is then

control

tube and hose A

in

620

and is introduced into the intake

ant

trol valve

con

exhaust manifold

in

E G R

con

be

in all

of the exhaust gas is led

chamber

thermal

Fig EC 46 Cheeking E A R volve

Warm up engine

valve

con

ET267

A

the

The exhaust gas recirculation sys tem consists of an E G R passage volve

Anti backfire valve

from

trolled

in the exhaust gas

tent To air

in

some

passage

spark flame temperature

during combustion This results reduction of the nitrogen oxide

installed

the E G R

open

EG R

the combustion chamber

to

also

is

When

DESCRIPTION

E AR

system

models except those bound for Coli fornia and Canada

If E A R valve does not function at above steps

control

when the

must

quickly

rpin

cetum it

pull or suction finger the anti backfire valve is functioning normally If no suction is felt replace the anti backflre to

idling

force

on

a

your

valve

2 3

E

C R control valve E C R passage

4

Intake manifold

5

Thermal

6

E C R

7

Exhaust

vacuum

valve

tube

manifold

EC349

Fig EC 4

Exhaust Gas Recirculation system

E G R

OPERATION Operation Fig EC 47 Checking anti backfire valve

EG R

E G R system operating water temperature oC OF Below 570C

of E G R

system is

as

shown below

135OF

Thermal vacuum

Intake manifold

E G R

vacuum

control valve

valve

Remarks

Close

Close california Non Above

Not actuated

Above 57 to 630C 135 to 145OF

Open Below

Actua ted

Above 57 to 6 oC 135 to 145OF

Above

Open

EC 19

MfT

models

Idling

only

70 mmHg 76 inHg California models and N on f alifomia AfT models 50 mmHg 197 inHg

Close Fullthrollle

Open

Emission Control E G R

OFF

When is low

operation

this

engine coolant temperature

recirculated exhaust gas

causes

irregular engine operation To prevent

be

System

recirculation of exhaust gas must off for a few minutes after

It remains closed while

engine um

has started

valve

is

thermal

The

provided for

engine coolant

temperature is low and keeps the E G R control valve closed thereby

cut

vacu

culling off the E G

this purpose

R circuit

rn

I

lW

11

1

L e7

r

Thermal

vacuum

Note

j E G R

2 is

When engine coolant temperature the working temperature of vacuum

The valve port

valve come

Throttle valve

close

valve

m

Vacuum condition EC227

clo

above

the thermal

I

controlval le

jS

to the top

Fig

of the

throttle valve

du ring

engine idling for improved idling operation At this point vacuum does not actuate

the

E GR

control

though

high

intake

i

manifold

actuated

vacuum

is

closed

valve

l

JllrI

L

r

E G

and E G R control valve remain

D T

J

49 EC

R not

t q

Throttle valve

II Thermal

E G R control valve

vacuum

valve

ope

close EC228

Fig EC 50 E G R 2

In the full throttle

tion the suction

vacuum

driving posi on

the

vacu

um um

passage does not surpass the

required

to

actuate

EC 20

vacu

the E G R

control valve

nol

actualed


6 Thermal

vacuum

valve

Open

I

Note

Vacuum condition

I E GR

control valve Close

EC793

Fig EC 51

E G R

ON

circuit

only when engine

Y

i3

m

m

not actuated

operation

E G R

The

E G R

is

is above

completed

coolant temperature

l fj ti

EN

the

thermal

3 0

1t

d

iiA

the

t1f

retor

working temperature of valve and carbu

vacuum

l

P@

0f Y

f

vacuum

Wg

i0

1 il

nk

suction

is

large enough

open the E G R control valve

to

i

1

Throttle valve

n

L Thermal

vacuum

Note

valve

r

Open

iiiI Vacuum

condition EC794

EG

E G R The the

R control valve

control valva EG R

control

valve controls

quantity of exhaust gas to be led through vertical

to the intake manifold

movement of the taper valve connect ed to the

diaphragm

Fig EC 52 E G R actuated

Open

to which vacuum

is

applied

in response to the

opening

of the carburetor throttle valve E G R control valve is installed

The

on

the

E G R passage through a gasket E G R con trol valve construction and type

vary with transmission

EC 21

type

and

car

destination For identification

the part number is stamped purposes on the recessed portion at the top of

the valve The

control

construction valve

is

of the

EG R

shown below

Emission Control

System the E G R

control

must

system

be

checked

j

The E G R warning system consists an odometer switch detector drive

of 0 o o

counter

E G R

harnesses

When the

o

m

o

warning earn

switch connected

eter o

lamp

and

in the odom

the

to

speed

ometer turns once for each OAkm 4

mile

the contact point of the elec

trica circuit closes

coil

allowing electric through the magnet

to flow

current of

detector

the

drive counter

Thus energized the magnet coil ac Wates the latchet to turn the c unter

l

2

Diaphragm spring Diaphragm

wheel by one pitch When the number of counts reaches 50 000 the latchet

3

Valve shaft

4

Valve

drops in periphery

1

l

@

5

6

Valve

Seat Valve cham ber

activate

a

provided

groove

of the the

detector

on

the

wheel to

counter

drive

counter

switch

EC231

Fig

E G R control value

EC 53

the

Then

EG R warning lamp indicating that the E G R

comes on

control system Should be checked The detector drive counteT is

ped Thermal The

vacuum

thermal

mounted

in

valva

vacuum

valve

is

the

engine thermostat housing It detects engine coolan t tem perature by means of a built in bi metal and opensor closes the vacuum passage in the thermal

vacuum

valve

with

When the vacuum passage is open the

when to

carburetor suction

system

to

the

diaphragm

trol valve

to

vacuum

valve is

taper

odometer which

service

E G R

the

equip

can

tell

contr0 I

After

completing periodic check to zero by hand proceeding as follows

con

the odometer

reset

valve

diaphragm

theconsiiiictlo vacuum

applied

of the EG R

actuate the

connected to the

is

an

nlie thermal

shown below

1

Remove

the

side

grommet installed on surface of detector drive

counter unit

2

insert

a

bar or

screwdriver

a

tip

into the hole from which grommet has

mt To E

G R control valve

been removed

li

provided

and press down knob

in the detector drive counter

for resetting The E G R warning

lamp

comes on

under the following circumstances From carburetor

1

When the number of counts has

reached 50 000 In this indicates that E G R

case

the lamp

control system

must be checked

When operating starter motor

2

1

Spring

2

Bi

3

Oring

Notes

metal

t 00

a

It is an indication of problem in the E G R

t

EC232

Fig EC 54 Thennal vacuum valve

warning lamp or problems point or in the harnesses if lamp does not light at 50 000

in the the

counts

b The E G R

warning system

ed independently of the E G R trol system

The E G R

warning system install

car

con

monitors the distance the

has travelled and indicates when EC 22

E G R

mounted those Canada

warning

system

is

all 620 models except bound for California and on

Emission Control

System

1

1

I

I

I

1

v

Ignition

v

I

I

I

I

switch

E G R warning lamp

f

I I I

Ignition I

switch

start

1

position

I I

Odometer switch

I

Fuse I

1 A r

I

I

I

I 0

I

v

I

I I I U

I I I I I I I

EC541

I

i lQ

Magnet coil

1

Fig EC 57 Removing E G R passage

mi

L

J

L

Detector drive counter

EC233

Fig EC 55 E G R warning circuit

3

Thermal

vacuum

valve

After removing the following parts vacuum valve can be dis

the thermal mounted

REMOVAL AND

Vacuum hose

INSTALLATION

mal

Remove air cleaner before

control

E G R

system

Vacuum

removing

For

Page

section

carburetor to ther

valve

hose

thermal

vacuum

valve to E G R control valve

removal

and installation of air cleaner refer to Air Cleaner

vacuum

Note

EF S

Drain

engine coolant before dis

mounting thermal

vacu

m

valve

EC234

Removal Fig EC 56 Removing KG R control valve

I E G R control valve After removing the following parts the

E G R

controi

valve

be dis

can

mounted Vacuum

valve

to

EG R

Note ten

To

hose

thermal

control valve mounting remove

vacuum

hose

vacuum

nut

flat

hose to

control valve and pull the

hose off with hand

E GR

pass ge

After removing the following parts the E G R passage can be dismounted

Exhaust gas

E G R control valve

clip connecting

EG R

vacuum

2

tube

return

exhaust

manifold to E G R passage B1ow by hose cylinder block

P

to

Fig EC 58 Removing thermal

v valve C

Vacuum hose

AB

valve to E G R

passage E G R passage

mounting bolt

EC 23

vacu um

valve

Emission Control EGR

4

System

warning system

CID

r

V

drive counter

1

Detector

2

E

3

Speedometer

G R warning lamp

EC251

EC 59 E G R

Fig 3

Detector drive counter

Detecfor

disconnect

counter

and loosen two bolts

securing detector

drive counter to hoodledge 2

E G R warning

COJUlector

w

as

E G R warning lamp

proceed

To

switch proceed

Cam in the

rotated

is

switch

speedometer

2

the

by

dismount odometer

as

follows as

Remove masking panel equipped with radio

On models

Loosen

4

screws

printed

Remove

odomete

type

switch

Remove lamp and socket as assembly Push and twist lamp off

and

dismount

securing speed

circuit housing then

speedometer

warning lamp from under in strument panel 2 E G R warning lamp is a twist remove

cover

screws to

plate

ometer to remove

E G R control system in

I

Make

thorough visual check

a

control

E G R

system

away oil to facilitate

If any hoses

are

of

If necessary

cracked

inspection or

broken

replace

Remove meter front

shadow

Checking

its mounted conditionS

wipe

Dismount combination meter

take off clips and 3

follows

1

odometer

speedometer

sembly

lamp

E G R warning lamp is mounted at the top cen ter of instrument pad To remove

back side of

I

panel

INSPECTION

Odometer switch Odometer switch is mounted on the

drive counter is secured

the top of R H hoodledge panel in engine room To remove detector drive on

y tem

warning

securing

switch to the back side of

speedometer

and

running engine warning system for

detach

odometer

an

check

With

E G R

sure

ing lamp lights

when

turned to START

proper

that E G R warn

function Make

ignition switch

position

is

starter mo

If E G R wanung lamp does

tor runs screws

two

2

inspect harnesses and con nectors or replace warning lamp Then turn ignition switch to ON position and check the following items

not

light

If odometer of detector drive reached 50 000 has not counter I

counts make sure that E G R

lamp does

not

light

If odomete

2

warning

of detector drive

counter has attained 50 000 counts

can

make

sure

that E G R warning lamp

lights If warning

lamp

check harnesses EC239

Fig EC 61 Removing odometer switch

tector

lamp

does

not

connectors

light

and de

drive counter replace warning detector drive counter if

or

necessary

InstaUatlon

Notes

EC554

Fig EC 60 Removing E G R warning lamp

To install

reverse

the removal pro

Operation is as

cedure

EC24

oC E G R

Collows

warning lamp

Emission Control

ON

START

Ignition Switch Position

Detector Drive Counter

E G R Warning Lamp

b After E G R

control system

be sure to

to zero

counter c

of

odometer of detector drive

reset

This item

applies

to all 620 models

except those bound for California and Canada 3

With

engine

stopped

inspect

E G R control valve for any indication of binding or sticking by moving dia

phragm a finger

of control valve

Below

Above

50 000 counts

50 000 counts

ON

inspection

completing

upwards

with

System

ON

OFF

With

4

E G R um

running

engine

inspect

control valve and thermal

vacuo

valve for normal

operation engine coolant tempera

When

1 ture

EC254

Fig EC 63 Checking lhermal

is low

valve

vacuum

Make sure that E G R control valve

does not operate when engine speed is increased from idling to 3 000 to 3 500 rpm

Place EGR

a

fmger

the

on

diaphragm

of

control valve to check for valve

operation

If any difficulty is encountered in judging the condition of any compo nent during above inspection check the questionable component independ ently as follows

E GR

control

Dismount

valve

E G R

control

valve

from engine I

Apply

valve

vacuum

referring

If the valve

to

to the

moves

E G R control

following figure

to full

position

it is

normal EG R open for vacuum

control more

valve will remain

than 30 seconds after

has cut off

la

EC253

Fig EC 62 Checking E G R control valve ET152

When

2 ture

I

is

engine coolant tempera

Increase engine speed from idling

high

Make sure that E G R control valve

3 000 to 3 500 rpm

operates when engine

Make

creased

from

idling

500 3 rpm Place diaphragm of E G to check for valve 2

control valve

If E G R

one

as

is in

3 000

fmger

on

control

to the

valve

operation

control valve

operate check Disconnect

a

R

speed to

does not

follows

end E G R control

valve side of vacuum hose connect ing thermal vacuum valve to E G R

su re

that

thermal

Fig EC 64 Checking E G R control

to

ualue

vacu um

valve is open and that carburetor vacuum

E G R

is

at

present

the

control valve side

end

of vacu

um hose

If

Visually check E G R control damage wrinkle or defonna

valve for tion

vacuum

is weak

all replace thermal vacuum

2

or

not present at

vacuum

is present

control valve

replace

valve

If

E G R

3

Clean

compressed matter

port

EC 25

the

seating

E G R control valve with

from

air

and

around

surface a

remove

the

of

brush and

foreign

valve

and

Emission Control

System

CATALYTIC CONVERTER

and

catalytic

converter accelerates

the exhaust gas and

to

changes them

carbon

dioxide

the item

to

This air is caUed

catalytic

harmful

Refer

air pump

the chemical reaction of hydrocarbons HC and carbon monoxide CO in

non

reac

process requires the proper a mount of air which is supplied by the

DESCRIPTION The

This chemical

H20

water

tion

secondary

converter

AJ S air

The

is mounted

on

vehicles destined for California

into

the

Refer

67 EC

Figure

C02 3

EC350

4

Fig EC 65 Cleaning E G R control valve

Thermal

vacuum

Dismount

valve

thermal

valve

vacuum

from engine

Note

Before

gine

Apply

vacuum

vacuum

response

to

to thermal vacuum

Thermal

to

a

sure

thaI ther

valve opens or closes in engine coolant tempera

1

Front tube

4

Main muffler

2

Catalyti

5

Rear tube

3

Center tube

vacuum

EC782

Fig EC 67 Location ofcatalytic converter

valve should open

temperature of 57 1450F completing

to

630C

the

135

car

OPERATION

not

allow

water

vacuum

to

get

inside the thermal vacuum valve

and

carbon

monoxide

in the exhaust gas are oxidized with oxygen 02

Exhaust gas emitted from the Do

He

ons

CO

passage

Note

converter

specified

ture as

at

en

engine

valve and check to be mal

drain

dismounting

coolant from

gine due

secondary

en

harmful

contains some harmful substances to

incomplete combustion

water

in the

combustion chamber The air injection system is designed to reduce the con

contained dioxide

exhaust manifold With this

secondary

air

carbon

dioxide

C02

and

H20

catalytic converter further engine exhaust gas Through catalytic action it changes residual hydrocarbons and carbon monoxide

In this system the secondary air is led from the check valve and injected

the

the

The

gas

injection of

in

air and converted into non

cleans

tent of such substances in the exhaust

into the

gradually

is

hydro

in exhaust gas into carbon

and water before exhaust gas

discharged

to

the

atmosphere

c Secondary air Carbon monoxide

hydrocarbon Carbon dioxide gas water

EC242

Fig EC 66 Checking hennal

EC444

vacuum

F

valve

EC 26

EC 68

Operution ofcatalytic

corwerter

Emission Control

INSPECTION Removal

and


2

REMOVAL AND

inspection

can

be

done as follows

System If CO percentage is still over step 15 catalytic conyerter is

16

in

connector and air check valve

03

disconnected

malfunctioning Replace catalytic

hose

Plug the prevent dust

to

from entering Refer to page ET 12 3 Check carburetor pipes for proper

con

verter

connection 4

Warm up engine sufficiently Race engine 1 500 to 2 000 rpm two or three times under no load then

Removal

5

Catalytic

converter

1

Apply parking brake

2

Place wheel lock under each tire

3

Jack up the vehicle Remove lower shelter of catalytic

4

Dismount

catalytic

INSTALLATION

If

7

converter

adjust

sary

it to

To install

specifkations

neces

Tightening torque Catalytic converter 2 6 to 3 4 kg m

Adjust idle adjusting screw until specified CO percentage is obtained B

19

Refer to page ET 12 9 Repeat the adju stment process as described in steps 5 to 8 above until

Note EC453

the removal pro

specifications

Refer

to page ET 10

specified

reverse

cedure

Bolt lightening torque

Refer to page ET 10 Check ignition timing

converter

5

engine for oe minute at idling speed 6 Adjust throttle adjusting screw until engine attains to specified speed run

to 25 ft Ib

CO percentage is obtained in step 9 should be engine has

Adjustment

made ten minutes after

Fig EC 69 Removing catalytic

wanned up

conuerter 10

Inspection

rpm

and make

Preliminary inspection check

condition

component

parts

including

tubes

Refer

of A IS

Inspection

to

of all

hos if necessary

replace

on

hose

catalytic

converter is nor

be

checked by ob

not

can

in CO

serving variation The checking procedure

Apply parking

percentage is as follows

brake

Shift

gears

into Neutral


and

or

Neutral

Park

for automatic

transmission 1

Visually check catalytic

for damage

or

cracks

to

that

specified

to

cap

and

2 000

CO per

connect

converter

air

air check valve

to

speed increases readjust it specified speed with throttle ad

13

speed pleted

FLOOR

TEMPERATURE WARNING SYSTEM DESCRIPTION

WaRn up

floor

The

screw

engine for about four

minutes at 2 000 rpm under

Catalytic converter or

500

If idling

12

mal

sure

Remove

11

justing

page EC 17

Whether

1

centage is obtained

Visually

and wires

engine

Race

two or three times under no load

noload

Measure CO percentage at idling After step 12 has been coin

sensing switch installed on the vehi cle s floor floor temperature relay and a warning lamp on the instrument

before

panel

making CO percentage measurement If CO percentage measured in 14 3 0 13 is less than the catalytic step

parts

wait for

one

minute

an

will

If CO percentage measured in 3 0 13 is over recheck A IS step and replace air check valve Then

driver

perform inspection

steps 12 and 13

EC 27

and wires that

connect

these

When the floor tempera ture rises to abnormal level the warning lamp

converter is normal

15

temperature warning temperature

system consists of a floor

light

to call the attention of the

The

system

and

location

of

of this

the

floor

sensing switch are ilIus Figures EC 70 and EC 71

temperature trated in

wiring diagram

Emission Control

System The

lamp

starting

lamp Ignition switch

motor

The

tween

IG

on

I I

Battery

J

Relay

J

floor

tis

operation The the ignition position chart furnishes the the

relationship

I

I

sa

while the

when

foUowing

information

T

on

is in

out

goes

switch is in

Ignition key Off

functioning

is

if it is remains

factorily I

temperatures

lamp and sensing

be

warning

switch

L

Floor

temperature 77 77

warning lamp

Floor temperature sensing

swi

tch

Contact close ECJ40

77 77

I

EC332

Fig

EC 70

Win ng diagram offloor temperature warning system

rl

Contaclopen

ECJ41

Fig EC 72 Operation of floor t mperature sen6ing

@

J

6witch

REMOVAL 1

Floor temperature

Floor temperature sensing switch 1

Remove seat section of

Seat

as

outlined in the

Body and Frame

service manual

2

Ij

floor

From EC556

temperature

sWitch

Floor temperature

cr Fig EC 71

Remove

sensing

under

this part Refer to

relay

relay cover

Figure

remove

EC 73

Location of iJoor temperature sensing switch

Floortemperature

OPERATION Floor temperature will exceed nor mal level when temperature rise in the exhaust

lytic

system succeeding

converter

is caused

engine malfunction conditions

or

the

cata

byeilher

severe

an

driving

Under this condition the

floor temperature sensing switch turns off causing the starting switch line of the floor temperature relay to turn off

and the ignition switch line to turn on result the floor temperature as a

warning lamp When lower

t

comes on

the an

the

floor

temperature

is

specific temperature

the

floor temperature sensing switch turns on The ignition line of the floor temperature relay turns off while the

starting switch side is in on The floor temperature warning lamp goes out EC 2B

EC783

Fig EC 73

Location of floor

ttmperature relay

Emission Control

System

Floor temparature warning

lamp Refer to

Figure EC 74 for

the loca

tion of this part

L

1t

1

RAt

Temperature warning lamp

Contact close

Off

Below 1050C

221 OF

Contact open

On

Above 1050C

221 OF

Note

Avoid

ture

If

sensing

To

install

perature sensing switch

order

the

of

Referring

s

step 3

connector

ignition switch

tester

Repair faulty wiring

replace

tem

When

relay trace

as

relay or check the Repair or replace

3

ignition

1

Check for continuity between ID Continuity should exist

@

Check for continuity between and@ Continuity should exist

CD

Check for continuity between

CD

and

ID

IG

Floor warning temperature

position and disconnect floor temper ature sensing connector The lamp

system

should remain on

parking brake

Apply

Shift

gears

into Neutral

foI manual transmission

and Neutral

or

for

Park

If not

Ensure

warning

floor

that

when

lamp lights

If

check

not

S

ignition position

J

back

to

replace

wire

CD

that

and

doc

@

replace

dn not

the floor

across

continuity and that

does not between

test results

CD

and

carrying

out the

Repair

O

temperature

4

5

To floor temperature

3

or

sensing

is

I

Remove rearseat

IG

Ignition switch position

3

Ensure

that

is turned to the

temperature relay

switch

When floor temperature

1

Float level

warning lamp lights

2

Choke

3

Normal fuel

Check

out

temperature proper

sensing

heater

to

areas

switch

ensure

of floor with

that

a

floor

glows when

temperature warning lamp floor is heated to the specifications shown in the table below

If

Fig EC 75 Checking floor temperature relay

floor temperature

warning lamp goes 4 Heat surrounding

@

ti

EC344

1760Fj before following procedure

2

exists con

satisfy the above

below 800C

cool

@ and

temperatwe

warning lamp From S position From IG position From ignition switch

2

s

if necessary

Be sure that floor

2

trace

switch

ignition

nuity

check floor

To floor

is burned out

If bulb is not burned

ensure

r I 141

bulbs

Replace bulb if bulb

to

should notexist

2 00

for burned

lamp

Continuity Apply a 12 volt

automatic

temperature

switch is iumed to the

@

between

temperature relay for continuity with

transmission 1

checking floor temperature remove it and proceed

for unit

follows

and

temperature sensing

switch to the

back

s

Floor temperature relay

2 INSPECTION

is normal

relay

to

switch may be heated through the floor by a proper heater Turn

following floor

trace wire

if necessary The floor

Note

removaL

back to

the

temperature relay

If con tinuity does not exist

wiring

to

if

perature sensing switch the

circuit tester

directly

If continuity should exist after heated surrounding areas of floor tem

wire

reverse

a

does not glow check floor

lamp

following INSTALLATION

switch

Floor temperature

floor tempera

heating

temperature sensing switch for continuity with a circuit

Fig EC 74 Location of floor temperature warning lamp

Temperature sensing switch

as

floor temperature

warning

lamp 1

Open

or

shorj circuit

in

wiring

harness 2

Check fuel system with regard to the following items Refer to Inspec lion of Fuel

System EC 29

supply

ry and secondary 4

Accelerator pump

5

Power valve

6

BC D D

7

Fuel strainer

8 Air cleaner

system

Prima

Emission Control 3

Check ignition system with regard the

to

Refer following Inspection of Ignition System items

1

Ignition

2

Distributor

to

AMP

3

Ignition coil

4

High tension Spark plug

5 4 to

System Note

code

come

Check idle CO adjustment

Inspection of

Even if there is

nothing wrong warning lamp may on if vebicle is being driven steep slope continuously in gears at high engine speeds

with engine the

on

Refer

a

lower

Idle CO

Adjustment

EVAPORATIVE EMISSION CONTROL SYSTEM CONTENTS DESCRIPTION

EC 30

CARBON CANISTER PURGE CONTROL

OPERATION

EC 30

VALVE

INSPECTION

EC 31

CARBON CANISTER FILTER

FUEL TANK

VAPOR

AND VAPOR

VENT

LIQUID SEPARATOR

The

evaporative

This reduction of hydro

IEC 32

VACUUM RELIEF

VALVE

EC 32

EC 31

carbons is

accomplished by

activated

charcoals in the carbon canister This

emission control

system is used to reduce hydrocarbons emitted to the atmosphere from the fuel system

FUEL TANK

LINE

DESCRIPTION

IEC 32

system

is

made

up

2

Vapor liquid separator Vapor vent line

3 to

the

4 Carbon canister

following

5

I

6 Canister purge line

Fuel tank with positive

sealing

filler

Vacuum signal line

cap

@

5

1

Fuel tank

4

Vapor vent line

2

Fuel nIler cap with vacuum relief valve

5

6

3

liquid vapor separator

7

Canister purge line Vacuum signal line Carbon canister EF274

Fig

EC 76 Schematic

drawing of

lIaporotive

emiaion

control6ydem

OPERATION Fuel vapors from the sealed fuel are led into the carbon canister

tank

The canister is fined with activated

when the

charcoals to absorb

See

30 EC

the fuel vapors

engirie is Figure EC 77

at rest or at

idlin ll

Emission Control

J

System

Close

at

Open

at rest

idling

i

i

j

J

17

f

Fuel vapor

1

Fuel tank

6

Canister purge line

12

Filter

2

Fuel f1l1er cap with vacuum relief valve

7

Throttlevalv

13

8

Engine

Liquid vapor separator Vapor vent line Vacuum signalUne

9

3 4

5

Carbon canister

15

Purge control valve Spring Diaphragm

10

Activated carbon

16

Fixed

11

Screen

14

orifice EC784

Fig EC 77 Evaporative emu ion control sy tem Fuel vapor flow when engine i6 at red or idling As

the

vehicle

throttle valve

speed

increases

opens and

vacuum

pres in the vacuum signal line forces

sure

rHL

the purge control valve to open and admits an orifice to intake manifold

intake manifold

through

the canister

purge line See Figure EC 7B

and fuel vapor is then drawn into the

JL I

I

J o

I Fuel vapor Fresh air

EC785

Fig EC 78 Evaporative emiuion control system Fuel vapor flow when engine i running manometer and a cock

INSPECTION

lent 3 way charge cock the vent line

FUEL TANK VAPOR LIQUID SEPARATOR AND I

VAPOR

Check

all

VENT LINE hoses

and fuel tank

Disconnect

the

liquid separator Connect

a

3 way

connector

a

Supply fresh line through until

mrnH20 14 5

vapor vent line connecting carbon canister to vapor 3

vent

little

mler cap 2

4

Shut

equiva

the end of

into the vapor the cock little by

cock

with 25 mmH20 0 98 inH20 8

When

completely

air

becomes

pressure 5 inH20

the

or an to

368

zero

in a short time

9

I f the

zero

and

hose

the

Note

height does

not

drop

to

in a short time when filler cap is

of

a

stuffy

In case the vent line is

stuffy

removed

completely

filler cap does not close the height should drop to

it

is the cause

leave it unattended 6

After 2 5

minutes

measure

height of the liquid in the manometer 7 Variation of height should remain EC 31

the

breathing

in fuel

tank is

thoroughly made thus causing

not

in

Emission Control System sufficient delivery of fuel to engine or vapor lock It must therefore be 1

3

connectur

repaired

or

replaced

368 mmH20 14 5 inH20

LL COCk

Air

Manometer

liqUid

IPO

36

@

epoo

ET37Q

r

Carbon canister

s2 EC

Fig

Replacing carbon canuter filter

EC786

Fig EC 79 Checking evaporative emmion control syatem

CARBON CANISTER PURGE CONTROL VALVE

3

If

cover

there

from

is

leak

a

check for dislocated Check for fuel vapor leakage in the distributor vacuum line at diaphragm of carbon canister purge control valve To check for leakage proceed as

If

phragm phragm

kit

retainer

a

remove

control

purge

or

necessary

top

valve and

cracked dia dia

replace

which is made up of

diaphragm and a spring

in

the

2

air into

the

it

Wipe

clean valve

housing

and have

Inhale air

A slight resistance ac by valve indicates that valve is in good mechanical condition Note also that by further inhaling air

companied

canister at Tconnector Inhale

see

it in your mouth

@

line between T connector and carbon

fuel filler cap and

Remove

functions properly I

Disconnect rubber hose

2

RELIEF VALVE

a

follows I

FUEL TANK VACUUM

@

opening of

rubber hose running to vacuum hole in carbon canister and ensure that there

the

resistance should

be

disappeared

with valve clicks

is no leak

3 1 2

Cover

3

Retainer

4

Spring

ance

Diaphragm

If valve is is felt

clogged or if no resist replace cap as an assem

bled uni t

ET350

Fig EC 81 Carbon catU ter purge control

valve

l

u

CARBON CANISTER FILTER Check for ET349

Fig

so EC

Checking carbon canuter purge control valve

a

contaminated element

Element

can be removed at the bottom of canister installed on vehicle

body

ET369

Fig EC 83 Fuel filler cap

32 EC

Emission Control

System


Tool number

No

Description tool

name

STI98 10000

For removing and installing the rotor ring assembly

For

Reference

use

page or

on

Figure No

L20B

Fig EC 29

A14

Fig

L20B

Fig EC 39

41 EC

Hexagon wrench

SE279

2

ST 19900000

For

assembling the

vanes

A14

Dummy shaft

SE284

3

STl9890000

Used

as

a

mount when rotor is removed and when bearing is installed

A14

L20B

Fig EC 32 fig IlC 35

L20B

Fig

A14

Fig EC 35

f

Rotor adapter

SE347

4

Used when rotor is removed and when front bearing installed

STl9940000

Bearing Pressing tool

d 9E348

This service tool is

designed for

use

in

disassembly

33 EC

and

assembly

of the air pump

EC 32

Emission Control

System

Tool number

Description

No tool name

5

STl9930000

Used

mount when front

as a

bearing is removed

For

Reference

use

page

on

Figure No

L20B

Fig

or

EC 33

Al4

E9

Bearing adapter

SE349

6

STl9910000

Used

as a

drift when front bearing is installed

Also used

as

a

support

when rotor is installed

L20B Al4

Fig EC 33 Fig EC 36 Fig EC 37

L20B

Fig EC 36

AI4

Fig

Bearing driver

SE350

7

STl9920000

Used

as a

drift when rotor is installed

C 37

o Rotor stand

SE351

8

ST19870000

Used as

a

adapter when air injection pump pressure is tested

L20B Al4

Air pump test gauge

adapter

SE389

EC 34

Page

EC 18

SECTION EE

ENGINE DATSUN PICK UP

ELECTRICAL

MODEL 620 SERIES

SYSTEM

BATTERY

STARTING

MOTOR

CHARGING CIRCUIT ALTERNATOR

TOKYO

LTD JAPAN

EE

4

EE 12 EE 15 EE 20

IGNITION CIRCUIT

EE 26


NISSAN MOTOR CO

2

REGULATOR

DISTRIBUTOR

I NISSAN I

EE

EE 30

DISTRIBUTOR California models

EE 33

TRANSISTOR IGNITION UNIT California models

EE 36

IGNITION COIL

EE 46

SPARK PLUG

EE 47

Electrical

Engine

System

BATTERY CONTENTS

LEVEL

ELECTROLYTE

CHECKING

CHECKING SPECIFIC GRAVITY

EE 3

BATTERY FREEZING

EE 2

REMOVAL

EE 2

CHARGING

EE 3

EE 2

INSTALLA TION

EE 3

REMOVAL I

Disconnect negative and positive

cables 2

Remove

clamps 3

from

nuts

battery

take off clamps

Read top level with scale

Remove battery

1 2

CHECKING ELECTROLYTE LEVEL

Fig

Remove six vent plugs and check for electrolyte level in each cell If nccessaJ pour distilled water

S

EE l

Checking pccme gravity

Converted specific gavity

Where St

520

20

of electrolyte

Specific gravity at

feOOl

20

0 0007 t

St

20

Thermal gauge

Hydrometer

1Je

tOe of electrolyte

Specific gravity

1 28

corrected at 200e 680F

@

Electrolyte temperature

S

126

t

For

example of 1 260

reading

would be

6goF

1 267

at

300e

corrected

indicating

to

fully

of

reading

Specific gravity of battery electro lyte is tested by a hydrometer If the

charged battery

srate of charge of battery is 60 or specific gravity reading is below 1 20

be determined by the following table if the specific gravity of electrolyte is

corrected

tery must

electrolyte Add

be

200e

680F

recharged

concentration

or

according

at

subtract

or

battery

gravity points or

made

A correction

by using

the

charge

of battery

BefOIe checking be

cells

filled to correct level

u

sure

U21101

can

1

I

dOldlOiJ

that

EEOO3

Fig

o N

b

below 200e

E

t

JI

u

ol

can

following

1

m I

I I

I

lilt

I

i

J Sf

J

0wJIztI

to

1

1 7

II

It

EE002

Fig

EE 2

EE 2

ffing ChaJ

I

100

COJJditioD

then be formula

OSQ

Electrolyte temperature oC

U

G

electrolyte

The gravity of electrolyte chlll ges 0 0007 for 1 80F tem every Ioe

petature

e 0

known are

o

l

adjusted

to whether the

temperature is above 680F standard

bat

u o

lOoe

1220 at

140 F would be 1 199 corrected to 200e 680F indicating a partially

as

l

a

CHECKING SPECIFIC GRAVITY

The state of

E l

860F 200e

charged hydro

battery On the other hand meter

Sow

hydrometer

A

condition

Specific lNWity at eiectroly te temperature

EE 3

Engine Electrical System nals should be cleaned with a brush and common baking soda solution In

BATTERY FREEZING indication that battery is

Battery electrolyte freezing point varies

discharged

specific

insufficient charge will freeze at lower a temperatures If specific gravity of

battery

11

below

falls

this

is

and

will

completely

freeze

readily when temperatures fall below freezing

with acid concentration or its gravity A battery with an

Note

Use extreme caution to avoid

freezing battery

an

since

freezing

will

generally ruin the battery

addition

be

following

the

I

Be

that electrolyte level is

sure

plate Keep removed plugs in a safe place Do not allow electrolyte tempera 3 I130F

After charging check to be cer tain that specific gravity does not Cor exceed 1260 at 200C 680P 4

20

rection

30

u

40

0

e

0

SO

I I

70 80

1 104

108

l2 t

1

16

t 20 of

24 1

28 1

1 32

After

all

vent

EEOQ4

electrolyte

Fig EE 4 Froezing point of electrolyte

INSTALLATION 1

CHARGING

Install and

tighten clamps

secure

Iy

electrolyte level is satisfactory battery must be charged when electro lyte gravity reading falls below 1 20 If If

car

necessary

plugs have been tightened clean all sprayed electrolyte off upper face of battery 6

Specific gravity

battery

as

Keep battery away from open flame while it is being charged 5

100

is

be made by adding dis

can

tilled water into cells

60

E

on

being

above top of each

ture to go over 450C 10

il

is

charged

2

0

g

items should

while battery

observed

quick charged

to

After clamps have been

it up to full charge the opera tion should be carried out with nega

2

clean

battery

tive cable removed

apply

grease

bring

Prior to

charging corroded

EE 3

termi

corrosion

cable to

tightened

terminals

and

retard formation of

Engine Electrical System

STARTING MOTOR CONTENTS

EE

4

OVERRUNNING

EE

6

BRUSH

CONSTR UCTI ON

EE

7

REMOVAL

EE

7

DISASSEMBL Y

EE

7

CLEANING AND INSPECTION

EE

8

TERMINAL

EE

8

FIELD

EE

B

EE

B


BRUSH SPRING TENSION

EE

B

TROUBLE

ARMATURE

EE

B

COIL

BRUSHES AND BRUSH

LEAD WIRE

ASSEMBLY

CLUTCH

ASSEMBLY

DESCRIPTION OPERATION

EE

9

EE

9

BEARING METAL

EE

9

MAGNETIC SWITCH ASSEMBLY

EE

9

ASSEMBLY

EE

9

TEST

EE

9

PERFORMANCE TEST

EE

9

MAGNETIC

EE

O

HOLDER

TEST FOR

GROUND

SWITCH ASSEMBLY TEST

EE

DIAGNOSES AND CORRECTIONS

EE 11

DESCRIPTION 5 @

The function of the starting system which consists of the switch to

crank

the

battery ignition

motor and solenoid

starting

engine

is

The electrical

supplied from the battery solenoid completes the circuit to

energy is

the

I

Brush

operate the starling motor and then the motor carries out the actual crank

2

Field coil

3

ing of the engine

4

Magnetic switch Pludgcr Torsion spring

5

9

6 7

Shifll

8

Pinion

9

Armature

r

Overrunning clutch

EE315

Fig

4 EE

EE 5 Sectioool view of slarting motor Sl14 180B

Engine Electrical System INHIBITOR RELAY

INHIBITOR SWITCH FUSIBLE LINK

A Y

O 1Y b

J

I

@

I A

rJ

BATTERY

f

l STARTING MOTOR

fB EARTH POINT

f

WBBYBY

rBW

B

@@@@

I

j

I

FUSIBLE lIN

000

ggg

I

I

California

Bd

CJ BW

f 00

00 00

H

r

For

I

T

BATTERY

BWI

000

00

Q

I

BW

I

@@@ Y

B

@

@

Y

BY

l

BY BW

BY

BWWB

BY

WB

BY

BY

@@@

@

@

@

@

I AfT

I

Black

OW

BW

@

Equipped with cooler

COLOR CODE B

I

BY

Black with white stripe Black with yellow stripe

W

White

WB

White with black stripe

9 IGNITION SWITCH

I M T

Equipped

with cooler

I

Notes a

b

@ @

T only M A T

only

Inhibitor switch is on

in neutral

L STARTER MOTOR

INHIBITOR SWITCH

eE491

Fig EE 6 Circuit diagram EE 5

0

starting systom

Electrical

Engine

System

OPERATION When the ignition switch turned clockwise to the START posi

cp

fully tion

battery

current

series and

shunt

solenoid

magnetizing

flows through coils the

of the solenoid

The plunger is pulled into the solenoid so

that it

move

operates the shift lever to

the

drive

flywheel ring

gear

pinion

into

the

I

Then the solenoid

switch contacts close

o

after the drive

1 W

r

pinion is partially engaged with the ring gear

Closing

of

the

solenoid

switch

Fl

contacts c uses the motor to crank the

engine and also

cut out the

coil of the solenoid of the hold

shunt

series

the magnetic

I

I

m

pull

coil being sufficient to

the

pinion in mesh after the been performed After the engine starts running the driver releases the ignition key and it automatically returns to the ON posi

EE274

shifting has

I

Ring

2

Shift lever guide

3

Armature

4

Battery

tion

5

Field coil

The torsion spring then actuates the shift lever to pull the pinion which

6

Stationary

contact

7

Monble contactor

8

Shunt coil

9 10

Plunger Ignition

11

Series coil

12

Torsion

13

Shift lever

14

Pinion

gear

switch

spring

allows the solenoid swi tch contacts to open

Consequently

the starting

Fig EE 7 Starting motor circuit

mo

tor stops

More

positive and meshing of the pinion and the ring gear teeth are secured by means of the

demeshing

overrunning clutch clutch

The

overruIUling

employs a shift lever to slide along the armature shaft

the pinion

6 EE

into

or

out of mesh with the

ring gear overrunning clutch is de transmit driving torque from

teeth

The

signed

to

the motor armature to the ring gear but prevent the armature from over

running after the engine has started

Engine

Electrical

System

CONSTRUCTION

V S 4

O

o

8

f

w

il I

jj

1

Magnetic switch assembly

13

Brush

2

Dust

t4

Brush

15

Yoke

3

Torsion

t6

Field coil

assembly

4

Shift lever

17

Armature

assembly

5

Dust

18

6

Thrust washer

19

Center plate SI14 1808 only Pinion assembly

7

E

20

8

Rear

9

Through

cover

Adjusting washer pring cover

ring metal

cover

bolt

10

Rear

tl

Brush holder

12

Brush

cover

assembly

spring

21

Dust cover Pinion stopper

22

Stopper clip

23

Gear

24

Gear

jl I

JI P

case

case

metal

EE316

Fig EE B

REMOVAL

4

transmission case

motor to

assembly forward and

starter

starting

er

@ @

draw

cover

3

connecting plate from

Remove

brush holder

two

screws

yoke assembly and with armature assembly and shift

s

7 Remove pinion stopper located at the end of armature shaft To remove

stopper

pinion Disconnect

away

hook

lever

E ring

and thrust washer

M

a

Remov

6

O

EE317

Fig EE 9 Remouing dUlt

I

bolts and

Remove brush holder

Pull

DISASSEMBLY

through

by moving each brush spring

from brush with

remove

motor

two

Remove b rushes from their hold

5

yellow

stripe from magnetic switch terminal and black battery cable from battery terminal of magnetic switch 2 Remove two bolts securing start ing

Remove

rear cover

Disconnect battery ground cable Disconnect black wire with

Exploded

view ofstarting motor

securing

assembly

first

move

and after

stopper

toward

removing stopper clip

with remove overrunning stopper clutch assembly from armature shaft

terminal of magnetic switch Re

move

switch

two screws and

securing magnetic magnetic switch

remove

assembly 2

Remove

thrust washer

dust

cover

E ring and

s

Pinion stopper Pinion stopper clip

EE318

EE277

Fig EE IO Removing brush holder d crt w

EE 7

Fig EE

l1

Removing pinion stopper

Engine Electrical System CLEANING AND

Check brush holders and spring cUp to

INSPECTION Clean all disassembled parts but do not use grease

since

such

deformed

not

are

properly

or

hold brushes

commutator

If brushes

or

brush holders

are

dirty they should be cleaned

solvent

a

would dissolve grease packed in c1u tch mechanism and would damage coils or EE017

other insulators

or

they

and will

against the

dissolving solvents for

cleaning overrunning clutch annature assembly magnetic switch assembly and field coils

if

see

bent

Check them for excessive damage wear and replace if necessary

Fig

EE I3

Testing rU ld coil for ground

BRUSH SPRING TENSION Check brush spring tension by a as shown in Figure EE 13

spring scale The

reading should be 1 6 kg 3 5 Ib Replace spring if tension is lower than I 4

kg

3 1 Ib

TERMINAL terminal

Check and

wear

for damage and replace magnetic switch

assembly if necessary

ARMATURE ASSEMBLY Check

FIELD COIL Check field coil for insulation the insulation of coil is damaged worn it should be replaced

If

1 or

for

continuity

tester

or

an

the

probe

of

a

circuit

ohmmeter to field coil

be

No

a

mica is less than 0 2 mm

from commutator surface

Check

the

surface condition

brush contact and

replaced or

with

sanded lightly

LEAD WIRE

holder circuit

If the

commutator

BRUSHES AND BRUSH

positive terminal and positive brush no

Inspect

sur

face of commutator is rough it must

loose contact is

If tester shows

of

appearance

500

emery cloth If the depth of insulating

Testing field coil

Connect

external

armature and commutator

continuity field

Check

found it

brush If a should be

mica should also be its

depth

worn so

mm

that its

0 472 in

length

is

wear

meter is

2

diameter of

replace

the connection of lead

is

clip

insulating

undercut

5 to 0 8 mm 0

so

that

0 01 97

to

0 0315 in The

Ifbrush is less than 12

coil is open

wear of

of

0 0079 in

31

mm

limit of commutator dia mm

0 0787

cammu

1 220 in

in

If the

tator is less than

replace

annature

assembly

and lead wire

o EE016

Fig EE I2 Testing field coil for continuity

@ TestIng field coD for ground Place onto

one

probe

of circuit tester

yoke and the other

coil lead

positive

EE018

onto field

tenninal

If very little resistance is read

Fig EE 14 Inspecting brush spring tension field

coil is grounded

8 EE

Engine

Electrical

System

L

l

File

0

L0

5 to 0 8

Commutator

mm

Segmen t

71j

IWMica

Ee026

Fig

EE 19

Testing brush for round

Incorrect

Correct

EE021

Fig EE 15

BEARING METAL

Undercutting i118ulating mica

Inspect bearing metal for side

2

armature

loose

using 3

connection

soldered

Inspect

lead

commutator

and

connection

is

found

of If

solder it

resin flux

Check armature for

continuity by

placing probes of tester on two seg ments side by side If tester shows no continuity the circuit is open

Armature test for

ground tester place

one test Using a circuit probe onto armature shaft and other

onto each commutator bar

If tester shows continuity is

5

grounded

and

must be

armature

replaced

play

bearing metal and more

sleeve

Screw sleeve must

along

armature

damage

shaft

is found

or

armature

shaft is

0 0079 in

replace

MAGNETIC SWITCH ASSEMBLY Using

a

circuit tester check con l

tinuity between S terminal of mag netic switch and switch body metal If

ASSEMBLY

Inspect pinion assembly and

than 0 2 mm

metal

1

OVERRUNNING CLUTCH

wear or

If the clearance between

screw

slide

freely If splines

resistance is felt

sliding it must be repaired Inspect pinion teeth If excessive rub bing is found on teeth replace Flywheel ring gear also must be in spected when

continuity does not exist shunt coit is opened Replace switch assembly 2

In

the

same

check continuity S

and

manner

as

between

above

terminals

If continuity does not

M

exist series coil is

opened

Replace switch assembly

ASSEMBLY EE022

Fig

EE 16

starting motor in re verse sequence of disassembly When assembling be sure to apply Reassemble

Testing annature for ground

to

grease 4

Check

placing with core

it

on

for

armature

armature tester

short

by growler

l

piece of iron over armature rotating armature If the plate

a

bearing pinion

gear

and

case

metal and

apply

rear cover

oil lightly to

EE278

vibrates armature is shorted

Fig

EE 18

Overrunning clutch auem bly

to

FOR GROUND

l EE023

Fig EE 17 Testing annature for ahort

PERFORMANCE TEST Starter motor should be

BRUSH HOLDER TEST

j

TEST

a

been

no

load

overhauled

Using a circuit tester place one test probe onto negative side of brush

performance

holder and another onto positive side If tester shows continuity brush

should also be

holder is shorted to ground brush holder EE 9

Replace

installed

when the

on

subjected

test whenever it to

will be

ensure

that

satisfactory

engine

Starter

subjected

to

has its

when

motor

the test

ofabnormal operation is to be determined A brief outline of cause

the test is given below

Engine load No

MAGNETIC SWITCH

starting

battery and of indicating

capable

Specified

in series

motor

12 volts

specified ammeter

an

System

test

Connect with

Electrical

tion

in

draw and revolu

current

these

test

shown

are

ASSEMBLY TEST

in Switch

Specifications

o

1 000 amperes

Switch

Battery

6

Starter motor

I

IB

Et

Fv

I

D Starter motor

Battery

EE351

FiN

EE 21 Circuit ofmagndic awitch

assembly If Ammeter

Voltmeter

the

OK Ee026

Fig EE 20 No load l ting

starting motor check magnetic switch

check

sembly

ted

Connect

cables

is as

between

negative battery tenninal and start ing motor M terminal positive battery terminal and starting motor S

terminal connecting a switch in as shown in Figure EE 21

series

Diagnoses of test Low

1

speed with draw

current

may

following 1 Tight dirty 2

no load

result

and high

from

the

or worn

bearings or

loosened

two

3

negative side brushes

from commutator c

Using

probe

place

one

input tenninal and the

onto

other onto yoke d

If

Weak brush

of mica contact

continuity

3

field

noload

separately

armature

determine whether field

or

to

armature

is

grounded 2

Fallure

current

draw

Low

arc

may occur

on

motor is

push pinion

l

measure

between pinion

front edge and pinion stopper The clearance should be held within 3 0 to 15

mm

0 012 to 0 059 in

If

neces

adjust it by changing or adding adjusting washer s Adjusting washers

commu tator

thrust out

biush

or

a

and

available in to two different sizes mm

0 020 in

and O S

mm

0 031

in

spring tension broken

rubber bush

are

5 0

commutator bar

between

clearance

on

all slack and

sary

operate

may be

with

high

caused by the

speed

and

draw

current

would

cause

internal resistance due to loose nections

to

in

the

the switch

to remove

loose

0 3 to IS

rom

0 012 to 0 059 in l

com

to burn

raise the other two brushes and check

and

out

back

mutator would cause commutator bar

indicates

tester

Burned

brush spring

circuit tester

a

for excessive

damaged commutator when operated with no load

A grounded armature or field Remove input tenninal Raise

commutator

burning In this case

Check armature further

b

Armature coil does not operate

2

Inspect

Shorted armature

a

trace

circuit with a circuit tester

field probe

4

open field coil

or

Inspect the connection and

Bent armature shaft

3

With

following A grounded I

mutator

damaged and

leads

causes

dirty

listed

on

low

high con corn EE029

item

Fig EE 22 MeO uring clearance

23

EE10

t

Engine Electrical System SERVICE DATA AND SPECIFICATIONS

Automatic

transmission

Optional

Type

Manual

for manual

transmission

transmission

S114 170B

SII4 ISOB

v

12

Terminal voltage

V

12

Current

A

Revolution

rpm

System voltage No load

Less than 60 More than 7 000

More than 6 000

Outer diameter of commutator

mm

in

More than 39 1 54

Brush length

mm

in

More than 12

Brush

spring tension

kg

3 1 to 4 0

4 to IS 1

Ib

47 0

Clearance between bearing metal and armature shaft

L

Clearance

edge

and

mm

Less than 0 2

in

O OOS

between pinion front

pinion stopper

mm

0 012 to 0 059

3 to 1 5 0

in


Condition

Starting

motor will

not operate

Noisy starting

motor

Discharged battery

Charge

or

replace battery

Damaged solenoid switch

Repair

or

replace

Loose connections of terminal

Clean and tighten terminal

Damaged brushes

Replace

brushes

Starti

Remove

starting

Loose Worn

Starting cranks

motor

slowly

Corrective action

cause

g motor

inoperative

solenoid switch

motor and make test

Tighten

securing bolt

Replace

pinion gear

Poor lubrication

Add oil

Worn commutator

Replace

Worn brushes

Replace

Discharged battery

Charge

Loose connection of terminal

Clean and tighten

Worn brushes

Replace

Locked brushes

Inspect brush spring holder

EE ll

tension or

repair brush

Engine Electrical System Condition

Starting cranks

Probable

Dirty

motor

slowly

Starting

motor

operates but does not crank engine

Starting motor will not disengage even if ignition switch is

Corrective action

cause

Clean and repair

or worn commutator

Armature rubs field coil

Replace assembly

Damaged solenoid switch

Repair

Worn pinion

Replace

Locked pinion guide

Repair

Worn ring gear

Replace

Damaged

Repair

solenoid switch

Damaged gear teeth

or

or

replace

replace

Replace damaged

gear

turned off

CHARGING CIRCUIT

charging

The

circuit consists of the

alternator

battery

wiring

necessary

and

regulator

to

these

connect

parts The purpose of this system is to convert mechanical energy from the into electrical energy which is

engine

used to operate all electrically operat ed units and to keep the battery fully

marks Then the warning lamp lights When the alternator begins to op

current flows from the

battery

current

is

coil

armature

This alternating current is rectified by the

and

positive

diodes

The

silicon

negative

rectified

direct

output reaches the alternator

When the ignition switch is set to ON

phase alternating

induced in the stator

E

charged

three

erate

the

reaches

the N

neutral and

E

voltage regulator N terminal to E terminal or ground through the coil VCI as shown in Figure EE 24 by

contact

IF

point

PI

P2

movable

voltage regulator

terminal alternator IF

rotor

field

terminal

the dotted line

arrow

shown in Figure EE 23 by full line arrow marks Then the rotor

coil

is

in the alternator

into contact with

terminal

switch L

tor

P5 nal

On the

flows from the

ground through the ignition warning lamp voltage regula terminal

and as

is excited

current

to

P4

point

E

as

other hand

battery

coil and alternator

lamp

movable

side contact

contact

voltage regulator

E

shown by dotted line

point termi arrow

VCI

movable contact to

turn

complete as

marks Then the

excited

contact

point

P6

point

and IPS

comes

This action

causes

off the warning lamp and the voltage winding circuit the full line arrow marks

by

When

the alternator or

excessively

the

Therefore

is

contact

P2

point Pin

contact

and

comes

into

again and the alternator Thus the rapid vibration of the movable contact point

voltage

speed

is

in

starts to rise

the movable contact point

EE 12

increases

voltage IPl

maintains

voltage

alternator output

an

constant

When the alternator increased

or

speed is further voltage starts to rise

the

excessively the movable P2

the

voltage winding side

shown

creased

VC2

applied into the rotor circuit and output voltage is decreased AJ the output voltage is decreased the primary side

side

point

coil

RI

movable

and

terminals nearly a half of the output and current flows from voltage

contact

of

registor

contact once

other hand

point voltage

force

A

ground through the ignition switch voltage regulator IG terminal primary to

separated from the primary PI by the magnetic

contact

current

terminals On

is

P2 side

into

comes

side

secondllJ

contact

contact

contact

point

point with P3

Then the rotor current is shut off and alternator output

immediately movable

voltage

This

contact

is decreased

action n

to

causes

separate

from

Thus secondary contact P3 rapid vibration of the movable contact point P2 or breaking and the

completing an

the rotor circuit

alternator output

voltage

maintains constant


l

r I I

i

I

Stator

ma

ture

r

coiJ

Ff

Ye

p

FF I I

Rot

L

R

Coil

field r

t

11 c I

vw RI

c

5

9

c

c

e

0

I

I

I

J

i

J Battery

u I

t

I J

Fusible link

8

t

J

1

Voltage regulator

Alternator

EE029

Fig EE 23 Charging circuit II

ns 1

p Slator

ar

ature

coil

teJ

I

Roto

field I

A3

coil

e

t

I

Lh

PS

L

A l

a o

l R r

R2

I

M H J

i

I

U 2iI g

I

I

j

U

V

It

g

t

Fusible link

0

t

Battery

f EE030

Fig EE 24 Charging circuit II

EE 13

Engine Electrical System B

v W WR WL

L2

VOLTAGE REGULATOR

co

WLI

I

LW

LW

IB P

cJ

r

m

I B WR

FUSIBLE LINK

t

EARTH POINT

CHARGE WARNING lAMP

00 00000

g

m

I

Equipped

WR

with cooler

m

I I I

CLB

TjT WB

B

YWR

I

I

I

W

I I W W

1

B

M

COLOR CODE

OW

Black with white stripe

W

White

WB WR

White with black stripe White with red stripe

WL

White with blue stripe

LO

LW

Blue with black stripe Blue with white stripe

Y

Yellow

BW

IG

IGNITION SWITCH

J

lOA C

Black

LW

j

rn ALTERNATOR

B

BwtIl

I l

M

0

0

o

0

0

0

0

0

o

0

FUSE

BLOCK

lOA

Ii

California models

E E492

Fig EE 14

EE 25 Circuit diagram of charging lfY t

m


ALTERNATOR


EE 15

INSPECTION OF

DIODE

EE 17

EE 16

INSPECTION OF

BRUSH

EE 1B

EE 16

SPRING PRESSURE TEST

REMOVAL DISASSEMBLY

EE1B

EE 16

ASSEMBL Y

EE 1B

ROTOR INSPECTION

EE 17

ALTERNATOR TEST

EE19

INSPECTION OF STATOR

EE 17


EE 19

INSPECTION

AND REPAIR

DESCRIPTION field is

like

the rotor which consists

that

In the alternator

produced by of alternator

pieces

magnetic

a

field coil

shaft

and slip rings

pressed

pole a

small field current Output current is in the armature coils located

generated in

the

stator

and

windings

alternating

The

stator

generates

has three three

electricity

current passes

easily

so

but

current is shut out

In this alternator

pack type silicon

Six diodes

three negative and three installed in positive and

positive are negative plates

tive and

They

negative conjunction mounted

are

plates which combine heat dissipating plate negative terminals

di odes are used

phase

current Silicon diodes act

way valve for

charging

reverse

The slip rings

in the shaft conduct only

a one

as an

These diodes

are

assembly direct soldered at

their tips and constructed with posi

weight

on

the

two

the function of and

and

are

positive light in

and easy to service

The

pulley mounted

on

the

air

conditioner models is different from that

on

the standard models

without

air conditioner

@God

A

tfff 3

2

4

I e

o

e

9

1

Pulley

usem

2 3

Front

cover

bly

4

Front bearing Rotor

5

Rear bearing

6

Stator

7

Brush assembly

8 9

Rear

cover

Diode

set

plate assembly

10

Diode

11

Through botrs

cover

EE345

Fig EE 26 Exploded view EE 15

Engine Electrical System REMOVAL

3

Remove

front Disconnect

1

negative battery

ter

Separate rear

cover

adjusting bolt

loosen

4

Remove alternator drive belt

5

Remove

6

Remove alternator from vehicle

associated

pulley

cover

screw

Disconnect

Remove A tenninaJ nut and diode and

nut

diode

remove

J CD

4 C EE035

O

assembly

Fig EE 29 Separating front with rotor from

cover

rear cover

11 4

Remove

bearing

three set

retainer

from front

screws

1

Diode

assembly

2

Diode

cover

Fig

EE 32

Note

Use

AJ e f

ecA

oo

EE039

Removing

diode 088embly

from

and separate rotor

cover

care

assembly

C

on

@@@

fIXing

assembly

J

and pulley

nut

diode

with

DISASSEMBLY Remove

cover

remove

installation

3

1

Remove diode

7

connector from alternator

parts alternator from engine

6 and

three stator coil lead wires from diode terminal with a soldering iron

wires and

lead

two

Disconnect

bolts

through

with rotor from

with stator by lightly tapping front bracket with a wooden mallet

minaL 2

cover

in

handling

to

an

diode

undue

st

it

EE033

INSPECTION AND

Fig EE 27 Removing pulley ond fan

REPAIR Remove

2

Remove and

screws cover

brush

holder

remove

fIxing

brush

remove

brushes

Q DO

holder

Pull brush holder fOIWard

holder

EE036

Fig EE 3D Removing rotor

and

together with brush

connect

5

Pull

rear

assembly

bearing

with

a

out from rotor

press

or

bearing

puller Note

When

and F

resistance

the

is

approxi

mately 5il the condition of brush and fIeld coil is satisfactory When no exists in brush

continuity or

when

significantly

from stator coil lead wire

car

tester between

tenninal and E terminal

coil

Do not disconnect N tenninaJ

from

alternator circuit

a

resistance

or

fIeld

differs

between those parts dis

assemble and inspect

L

I

EE037

E

A

O

o

1 EE346 1

N

terminal

2

Brush

3

Brush holder

Fig

EE 28

ld

holder co

Q r

Remouing

brush

Fig

EE 3I

Pulling

out of roar

EE 16

bearing

EE040

Fig EE 33 Inspecting alternator

Electrical

Engine

1

rotor

as

there is

slip rings of Figure EE 34 If

between

shown in no

If each

test of rotor coil

Continuity Apply tester

continuity field coil

is

INSPECTION OF DIODE

Ground test

2

ROTOR INSPECTION

System

lead

tive

with

of stator coil

wire

including neutral

wire

stator

stator coil is

condition

core

If there

satisfactory

is not conduc

is

is

continuity

grounded

rotor

assembly

A total are

of six diodes

mounted

plate

The

performed

on

Stator

core

used three

are

positive EEl plate are on the negative e

on

the

continuity

terminal and

EE041

continuity test on diodes using an ohmmeter

a

and other three

open

Replace

Perform

in both directions

test

should be

each diode between the

plate

Ee044

Fig EE 37 Teding stator for

Fig EE 34 Continuity

test

of rotor

Ound P

coil

Ground test of rotor coil

2

Check continuity between slip ring and rotor core If continuity exists

replace coil

or

rotor

assembly may be

slip ring

Conductive direction

because rotor

grounded

I

I

plate ptate

2

Diode

3 EE045

Fig EE 35 Testing rotor coil for

diode Fig EE 38 Conductive direction of

round

INSPECTION OF STATOR 1

Continuity Stator

is

continuity

test

normal

when

there is

between individual

coil tenninals

stator

When there is no conti

nuity between

individual

terminals

cable is broken

Replace with

stator

assembly

Diode

positive flowing

installed

on

EEl

plate

is a

diode

which allows current

from

terminal to

EEl plate

only In other words current does not flow from EEl plate to terminal

Diode installed

on

e plate

is a

negative diode which allows current from e plate to terminal

flowing

only In other words flow from terminal to

current does not

e plate

v

1 2

EE043

Fig EE 36 Testing stator for continuity

Fig

ptate Terminal

EE046

EE 39 Inspecting positive diode

EE 17

I

plate

2

Terminal

EE047

diode Fig EE 40 Insp cting negative

Engine Electrical System flows in both positive

If current

If there is

and negative directions diode is short If current flows in one direc

circuited tion

diodes

only

diode is in

Test

See

good condition

probe

a

ix

faulty diode

diode

as

table below

an

replace all assembly

These diodes

are

unserviceable

Reassemble alternator in the sequence

of

carry out the

2

terminal

EEl plate

EJ plate

terminal

terminal

e plate

e plate

terminal

o

e plate

@ plate

o

Xl plate

e plate

o

movement is not smooth check brush

holder and clean if necessary

measure

If it is

worn

Check brush pig tail and

if dam

aged replace Brush

wear

use

of a

255 to 345 gr

0 7

line

02

per 1

A

terminal bolt

3

Diode

4

Rear

5

Diode

cover

cover a

sembly

Fig

EE 43 Sectional view of diode and A term inal

brush spring is

9 0 to 12 202

Morevover

when

pressure decrease

limiting

new

pas

EE347

brush spring pressure by the pring balance Normally the

rated pressure of a

as

Imulating bush

2

With brush projected approximate ly 2 mm 0 079 in from brush holder

wear

fast

When installing diode A terminal

1

Check brush for

as

install insulating bush correctly

SPRING PRESSURE TEST

down to less than the specified limit replace brush assembly

operation

sible

Gl

Check movement of brush and if

the

I When soldering each stator coil lead wire to diode assembly terminal

Conduction

INSPECTION OF BRUSH

reverse

disassembly noting

following

of a circuit t ter

e

ASSEMBLY

brush is

worn

approximately

mm

0 0039 in

20 g

3

Tighten pulley

29 0 ft Ib

wear

make

sure

is less than

t

m

nut with

tighten

3 to 25 kg m When pulley is tightened

ing torque of

3 5 to 4 0

that deflection of V groove 3 mm 0 01 IS in 0

0 079 in

q or f

Fig

EE 41

Bnlsh

wear limil

t ffl

EEO 9

EE127

Fig EE 42 M

uring pring preaure

CJ

EE lB

Fig

EE 44

EE051

Tightening pulley

nut

Engine

Electrical

System

ALTERNATOR TEST Before test

conducting

make

an

th tthe

sure

A

alternator

battery is fully

test

charged

30 V olt voltmeter and suitable

probes

Set up

3re

a

Figure EE45 and

necessary for the test

test

circuit as

shown in

manner

indica ted

test auernator in the in the flow chart

below

Disconnect connectors at alternator

1 2

Connect

3

Connect one test

Make

sure

A

terminal to

F

terminal

probe from voltmeter positive terminal to that voltmeter registers battery voltage

terminal Connect the other test probe

4

Turn

5

Start engine Increase engine speed gradually until it is approximately 1 100 rpm and take the voltmeter reading

6

on

headlights

Measured value

and switch to

A

ground

High Beam

Below 12 5 Volts

Alternator is in trouble

to

remove

Measured value and check it

Over

5 Volts 12

Alternator is in good condition

for condition

Notes a

Do Dot

run

engine

at the

speed

of

more than 1 100 rpm while test is being conducted on alternator

b Do not

Battery

i

9

race

engine

l

IV

I

Voltmeter

EE052

Fig EE 45 Testing alternator

SERVICE DATA AND SPECIFICATIONS IB LT138

Type

For air conditioner

LTl35 36B

Nominal rating

V A

1235

12 38

Negative

Negative

Minimum revolution when generating 14V with no load rpm

1 000

1 000

Hot output current

28 2 500

30 2 500

35 5 000

38 5 000

2 25

2 25

Ground

Pulley

polarity

Nrpm

ratio

Brush

Length Spring

pressure

mm

in

gr

oz

More than

5 0 295 7

255 to 345

diameter

mm

in

More than 30 EE 19

5 0 295 7

255 to 345

9 0 to 12 2

Slip ring outer

More than

9 0 to 12 2 181 1

More than 30

181 1


REGULATOR CONTENTS EE 23


REGULATOR

VOLTAGE ADJUSTMENT REGULATOR

VOLTAGE

RELAY

CHARGING

EE 20

DESCRIPTION MEASUREMENT OF

EE 24

DIAGNOSES AND

EE 20

TROUBLE

EE 23

CORRECTIONS

Including alternatorl

EE 25

EE 23

DESCRIPTION The regulator consists

basically of a

field circuit direct to ground and the upper contacts when closed the field circuit to ground

voltage regulator and a charge relay The voltage regulator has two sets of points

contact

a

lower set and

resistance

an

field coil

upper set to control alternator volt age An armature plate placed between

alternator output The charge relay

the two sets of contacts

construction to the

downward

or

or

vibrates

when closed

contacts

moves

upward

The

and

similar

i

charge warning lamp goes

the

v

produce in

voltage regulator

When the upper contacts

lower

complete

complete through a

are

closed

1

Charge relay Voltage regulator

2

on

46 EE

Fig As

EE285

View of removing cover

regards

the construction

voltage regulator is very similar charge relay as shown in Figure

@

IjDC@V

@

I

GJ

J

CD

@

@

j

@

@

@

@ 10

3111111 0 118 ill 41l1I11W 157in

Armaturc

II

Cuil

Core go

12

lock

J3

Y kt

9

3 4

5

Low

h

Point

7

High speed

8

Contact

gp

Sllccd

lnlacl

ap conlat t

Tlll tion Cnl1

t

T

di c1ia

few

CD

r

L

@

1

gf

@

@

I

Point gilp

2

Charge relay

EEJ97

9 contllct

Adjusting

10

Lock

screw

nut

3

Core gap

11

Coil

4

ArlllatlJre

12

4mm

5

Connecting

13

3mm

14

Adjllslin screw Adjll sting sprin

6

14

Contact iet

15

Yoke

7

Yoke gap Yoh

15

Voltage cgulatm contact

B

Adjusting pring

nut

c

a

Jb

EE47

ID@

r

@

2

ID@ @

L

r

I1Jlccting spring

J

Q

f

lltagl l

jllIOltllT

b

sprin

0 157 in dia 0 118 in dla

screw crew

Construction of charge relay

Fig EE 20

the

to the

EE 47 Structural vi

w

Engine Electrical System MEASUREMENT OF REGULATOR

Rqulator

VOLTAGE Genera tor

Regulator voltage is measured with regulator assembled with alternator When measuring voltage with regulator mounted rotate

on

engine

Connect

at

cables I

is

necessary

A

to

rated

at

25W

radio etc

are

circuit Short

a

with

here

starting the operation IG

lamps

B

i

air conditioner

turned off

V

2

Before starting engine be sure to make short circuit with a cable be tween

between

Fuse box

Check to be sure that all electrical as

Wire harness fuse side tenninal and terminal of ammeter before

shown

loads such

Connector

iJ

r

high speed

l5 30A battery and

resistor as

it

DC voltmeter l5 30Y

DC ammeter O 25fl

car

Voltmeter

Ammeter lOA

30V

fuse side terminal of resistor EE055

O 25fl

and negative side terminal of ammeter Failure to follow this pre

Fig EE 48 Measuring regulator voltage with regulator

caution will cause needle of ammeter

swing violently resulting aged ammeter to

in a dam

3

Refer to the

determine

following

if regulator

EE 21

and

chart

to

relative

parts are

in

good condition

on

vehicle


I

Start engine

2

Rotate engine at 2 500 rpm for several minutes

Mter racing for several minutes ammeter reading

After racing for several minutes

below SA

Fully charged battery available I Replace with fully charged battery 2

Check to

see

ammeter

5A

reading over

Fully charged battery not available I

Connect

0 25 ohm resistor in series

a

if current falls below SA

Current falls below SA

Current does not fall below SA

Recharge battery

and

see

if current falls below

SA

Reduce engine speed to

idling

and then raise it to 2 500 rpm while observing needle of voltmeter

Needle of voltmeter held within limits shown in the below table

Needle of voltme ter

Regulator functioning properly

Adjust

Regulator type

ou t

of limits shown in

the following chart or

replace regulator

TLI Z 85C

speed c

Temperature Oc

OF

Voltage

V

may be approximately higher than rated for two to

Voltage 3V 0

three minutes after 10 14

14 75 to 15 75

0 32

14 60 to 15 60

10

50

45 14

to 1545

ed

14 30 to

30 86

14 15 to 15 15

40 104

14 00 to 15 00

30 15

lator becomes self heated Measure minute after

3

Do not measure

ly

after

regulator voltage immediate

driving

Do this while

b

To

is cold

voltage raise engine speed gradually from idling to rated measure

EE 22

starting engine

or

when regulator is cold

regulator is of a temperature compensating type Before meas uring voltage be sure to measure surrounding temperature and cor rect measurements according to the

d The

table at left Notes

engine is start specifically when regu

ments should then be made within one

20 68

or more

Engine Electrical System ADJUSTMENT

4

VOLTAGE REGULATOR regulating voltage

When

as

meas

adjust regulator

tact

Adjust

necessary gap

core

in that order

required 3

and

upper con

as

necessary

upward

See

Figure

EE400

035 to

45 0

mm

D1S O

0 014 to

in

if

adjust

gap and

point

Fig EE 51

is

adjustment

No

secure

upper contact

move

in

Point gap

Inspect contact surface and if rough lightly polish with fine emery paper 1 500 or 600 I

Measure each gap

lIS O

mm

EE 50

in accordance with the

following instructions

2

used to

and

downward

or

3

screw

diameter

deviates from rated value

ured above

CD

Adjusting point gap Loosen

I

Wrench

2

Crosshead screwdriver

3

Adjusting

4

l ock nut

AdjUJJting

screw

Ulating rel

voltage

for yoke gap

Adjusting core gap Loosen

mm

which is used

contact set

upward

4

screw

diameter

on

Figure

in

to

secure

yoke and move

contact

downward

or

0 157

CHARGE RELAY Nonna relay operating voltage is S

See

properly

to IOV as measured at alternator

EE399

49 EE

Core gap

I

Thicknes

2

3

0 6 to 10 mm

mm

gauge

0 118 in dia

screw

3

0 024 to 0 039 in

4

Use screwdriver

Sshelld Cro

Upper

a

DC voltmeter and set up Figure EE 52

contact

Adjust

Adjusting voltage Adjust regulating

point

voltage

manner

gap

as

charge relay in the same that for voltage regulator

as

follows Loosen lock nut securing EE398 I

Contact set

2

ThicknesJ gauge

3

4

4

Crosshead Jcrewdriver

mm

0 157 in dia

Turn this

increase

core

screw

adjusting

clockwise to

counterclockwise

or

decrease

screw

Fig EE 49 AdjUJJting

L

screw

regulating Figure EE 5 J

to

See

voltage

gap

Connect positive tenninal of voltmeter to

regulator

lead connector

N

tenninal with negative terminal

grounded 2

Start engine and keep it idle

3

Take voltmeter

reading

I

Check

tween

for

continuity be

terminals

of

re

gulator and alternator 2

Alternator circuit inopera

tive if

continuity

Over 5 2 Volts

Below 5 2 Volts

o Volt

Charge warning lamp I

Check fan belt tension

2

If correct

and

adjust

as

Charge warning lamp on Charge relay coil or contact

on

remove

necessary

regulator

points out oforder Replace regulator

exists

Over 5 2 Volts

Charge warning lamp off Charge relay assembly is in good condition

EE 23

a

circuit as shown in

Fig EE 50 Adjusting

5

A

tenninal Relay itself however oper ates at 4 to 5V


RegulatoI

Yellow terminal

r

L WR

A W

IG WL

Voltmeter

N

Y

E B

F

WB

EE348

Fig

EE 52 Tuting

charging

Qy re

SERVICE DATA AND SPECIFICATIONS Voltage legulator Type

TLl Z S5C

Regulating voltage Voltage

fully charged battery

inserting

5 at 200C 680F 10

resistance

fl

coil series resistance

Smoothing

10 31

resistance

40

COle gap

nun

in

Point gap

nun

in

uge Ch

3 to 15 3 at 200C 14

v

coil resistance

RotOI coil

Voltage

with

0 6 to 1 0 0024 to 0 039 35 0

to

45 0

0 014 to O OIS

lay

Release

voltage

V

4 2 to 5 2 at

Voltage

coil resistance

fl

37 S

at

N

terminal

200C 680F

Core gap

nun

in

0 8 to 10 0031 to 0039

Point gap

mID

in

4 to 0 6 0016 to 0 024 0

Standard tempelatUIe gIlIdient

EE 24

O OISV oC

680F

Engine Electrical System TROUBLE

DIAGNOSES AND CORRECTIONS Including alternator Probable

Condition

No output

Sticking brushes

Correct

Dirty brushes and slip rings

Clean

Loose connections or broken leads

Retighten or soldef connections Replace leads if necessary

Open

sta tor

winding

Repair

Open

rotor

winding

Replace

Open

diodes

Shorted stator

Repair terminal

or

Broken neutral wire COIOf of wire is yellow

Replace

Voltage fegulator breakdown

Check

Poor

grounding of alternator regulator En terminal

output

Loose

or

worn

wire

voltage

and

color of wire is black

regulator operation required

Sticking brushes

and

repair

or

as

Retighten

terminal connection

Replace Retighten

fan belt

replace

insulator

Replace

replace

Low

stator

rotor

Replace

ground

replace

rotor

Broken fan belt

Broken

replace brushes and brush springs

Replace Replace

A

or

Of

Shorted rotor

Grounded

Excessive output

Corrective action

cause

Correct

or

or

replace

replace

brushes and springs if

necessary Low brush

Replace

spring tension

Voltage regulator breakdown

short

springs

Check

regulator OpefatiOn replace as required Clean

Dirty slip rings Partial

brush

ground

or

open

in

stator

Replace

stator

Replace

rotor

Replace

diode

winding Partially shorted Open Noisy alternator

or

or

grounded

rotor

winding

damaged diode

Loose mounting

Retighten bolts

Loose drive

Retighten

pulley

Replace

Broken ball bearing

Improperly

Seat correctly

seated brushes

EE 25

and

repair

or

Engine

Electrical

System

IGNITION CIRCUIT CONTENTS NON CALIFORNIA

MODELS

EE 26

CALIFORNIA MODELS

EE 2B

NON CALIFORNIA MODELS The ignition circuit consists of the

ignition

switch

wiring spark plugs The resistor

coil and

distributor

battery

circuit

is equipped During cranking

with

secondary winding of the ignition coil high tension wiring distributor rotor

cap

and cap

high voltage

When

a

electrical

on

bypasses the resistor thereby connecting the ignition coil directly to battery This provides full battery voltage available at coil and keeps ignition voltage as high as possible

are

current

The low

voltage current is supplied battery or alternator and flows through the primary circuit It consists the of resistor ignition switch primary winding of the ignition coil distributor contact points condenser and all connecting low tension wiring The high voltage current is pro duced by the ignition coil and flows through the secondary circuit result ing in high voltage spark between the electrodes of the spark plugs in engine cylinders This circuit contains the by

the

the

ignition switch

is turned

and the distributor contact

points

closed

through

the primary current flows the primary winding of the

coil and

through

the contact

points

to

ground When the contact

points

are

opened

by the revolving distributor earn the magnetic field built up in the primary winding of the coil moves through the secondary winding of the coil inducing high voltage The high voltage is produced every time the contact points open The high voltage current flows through the high tension wire

Then the spark obtains while the current jumps the gap

between the insulated electrode and the

ground side electrode of the spark plug This process is repeated for each power stroke of the engine The distributor contact point and

spark plugs should be inspected clean and regapped at tune up They should also be replaced periodically as ed

ule

current

spark plug terminals

to

one

of the

in the distributor

Maintenance Sched

In addition

consistency equivalent

No

MoS2

or

I

apply grease NLGl containing MoS2 or

distributor

to

MIL

grease

shaft and

G l0924B

equivalent

containing

to

cam

as

reo

quired

to the distributor cap Then the rotor

distributes the

in the

specified

The

remainder

of

the

ignition

component parts should be inspected for only their operation tightness of electrical terminals

and wiring

con

dition The ignition circuit is shown below

0

cl

IR IB

Battery

is

g J

Re5istor

I 21

To starter

Ignition

coil

Secondary winding Cap Breaker

point

f Rotor

head

Distributor

EE060

Fig EE 53 Ignition ydem circuit diagram EE 26

Engine

E

Electrical

System

CJI2t W

R

o

Bf

00 00

fOl

FUSIBLE LtNK

m

Wj

BW

BR

I

R BL

IGNITION SWtTCH

DISTRtBUTOR

L oj

RESISTOR

ti

J C L

IGNITION COIL

jjj

COLOR CODE B

Black

OW

Black with white stripe Black with red stripe

DR aL

Black with blue stripe

W

White

SPARK PLUGS

EE493

Fig EE 54 Circuit diagram ofignition ByJt EE 27

m


Engine Electrical System CALIFORNIA MODELS The ignition circuit consists of igni switch transistor ignition unit

tion

distributor

wiring

spark plugs and

battery The distributor is of the contactless

type

and

is

equipped with

pick

a

up

coil which electrically detects the igni tion

timing signal

circuit

breaker

in

of the

place

of the

conventional

distributor The transistor ignition unit is a new addition which generates the

signal required

for the make and break

of the primary electric ignition coil The

circuit

current

for the

primary winding of the igni transistor ignition unit and all connecting low tension wiring The high voltage current is pro duced by the ignition coil and flows through the secondary circuit result ing in high voltage spark between the electrodes of the spark plugs in engine cylinders

voltage

tion coil

primary circuit opens The high voltage

This circuit contains the secondary winding of the ignition coil distribu tor high tension wires to coil and

high

spark

plugs

distributor rotor and cap

When the

is

equipped with a resistor During cranking electrical current bypasses the secondary resis tor thereby connecting the ignition coil through the primary resistor This makes battery voltage available at ef ficiently and keeps ignition voltage as high as possible The primary resistor selVeS to pro tect transistor ignition circuit The low voltage current is supplied by the battery or alternator and flows through the primary circuit It consists of the ignition switch

on

ignition switch is turned

and the distributor reluctor rotates

the

primary current flows through the primary winding of the coil and through transistor ignition unit to ground When the prim ary circuit is opened by circuit of transistor ignition unit the magnetic field built up in the primary winding of the coil moves through the secondary winding of the coil inducing high voltage This high

produced

the

high

every

Primary winding

current

terminals in the distributor cap Then the spark occurs while the

voltage

between the

current

jumps the gap insulated electrode and

the ground side electrode of the spark

plug

This process is repeated for each

power stroke of the

engine

plug should be inspected cleaned and regapped at tune up Spark plugs should also be replaced periodically as specified in the Main The spark

tenance Schedule

The remainder of the ignition

butor tightness ofelectrical terminals and wiring condition

Apply grease NLGI consistency I containing MoS or equivalent

Secondary

To starter

I

Secondary winding

r

ignition

I

unit

I

Pick up

rcoil

oi r

Rotor head

nl

R5 1 U1f Retuctor

r

J l

f

S

park plugs

EE287

Fig EE 55 Ignition 8Y3tem circuit diagram EE 28

com

ponent parts should be inspected for only their operation air gap of distri

Resistor

Transis tor

flows

distributor cap then the rotor distri butor cap then the rotor distributes the current to one of the spark plug

I

1

time the

tension wire to the

to distributor rotor shaft as

Primary

Ignition

through

No

Battery

coo

is

resistor

required

Electrical

Engine

TRANSISTOR

IGNITION

System

UNIT

IHIIl II II

BW

BBV

EARTH POINT

RG

I I

r

BW

111 a

lof1

B

@ 00

00

W

SR

00 00 00

b

Et

liiI

FUSIBLE LINK

BATTERY

TERMINAL BLOCK

c r

B BR

ml lliJ LldJ0 IGNITION SWITCH

d

L

j

ilR

@ BW

c

l

i

in

10 i9

RESISTOR

D1STRliUTOR 0

IGNITION COIL

COLOR CODE 8

DR

Black Black with white stripe Black with red stripe

W

White

L

Blue

R

Red

G

Green

OW

J

SPARK PLUGS

EE494

Fig EE 56 Circuit diagram of ignition system EE 29

California models


DISTRIBUTOR

Non California models CONTENTS

CONSTRUCTION

EE 30

ADVANCE

CHECKING AND ADJUSTMENT

EE 31

DISASSEMBL Y

EE 32

EE 31

ASSEMBLY

EE 32

CONTACT POINT

EE 31


EE 33

CONOENSER

EE 31

CAP AND ROTOR

HEAD

MECHANISMS

EE 31

CONSTRUCTION The distributor consists of breaker

plate with

contact

points centrifugal

advance mechanism

vacuum

control

ler distributor shaft and rotor

D

@

v

i @

t

Cap assembly

2

Rotor head assembly Condenser assembly

3 4

5

Ground wire assembly Lead wire assembly

6 7

Contact set

8

Packing

Breaker plate assembly

9 10

earn assembly Governor spring

11 12

GoVernor weight Shaft assembly

13

Vacuum controller

14

Terminal assembly

IS 16

Housing Fixing plate

17

Oring

IS

Collar

D @

EE32Q

Fig EE 30

EE 57

Engine Electrical System CHECKING AND

First turn

wire connection

Cap and rotor head should be in as

spected periodically

specified

in the

Remove cap Maintenance Schedule and clean all dust and carbon deposits from cap and rotor or

If cap is cracked

leaking replace with

is

a

Deone

with

accordance

the

in

Maintenance

Standard point gap is O OIS to 0 022 in

mm

fingers

holding

pull

contact

out

by

arm

toward

set

contact

by

of insulation sure

it

on

capacity

con

degree

attention to be

requiring

that terminals

of

and

clean and

are

set

tight

screws are

Checking of condenser

is made

by

a

condenser tester

Contact

raising slightly point and afm can then be removed together

you

new

contact

point and

arm

in

reverse

sequence

of

assembly

removal Coat cam with

a

light coating

45 0

to 0 55

In case size

ADVANCE MECHANISMS

Specifications

adjustment is made by loosening point screws Gap gauge is required for adjustment When point surface is rough take off any irregularities with fine sand is off the standard

paper of No

wear

Application

points is points together To replace proceed

on

with contact

arm

D4A4 07

D4A6 07

D4A6 0S

Manual transmission

transmission

contact

Vacuum advance

replace

noticeable

D4A4 06

Automatic

500 or 600 or with oil

stone

as

denser depends

of grease

Schedule

When

Satisfactory performance

to

lead wire

While

Install

replaced

just for enough

out

remove

CONTACT POINT Contact point should be

CONDENSER

primary lead

primary lead terminal Referring to Figure EE 59 unSCrew two contact set fixing screws and pull

CAP AND ROTOR HEAD

1 5

set screws 1 to

contact arm and

turns at

ADJUSTMENT

out

00 30

Distributor degrees distributor

91

150

5

250

9 S4

6

00 170 6 69 50 300 1I S1

mmHg inHg

follows

Centrifugal advance Distributor degrees

00 600 110 1 950

00 550 11

0

distribu tor rpm

2 300

For Canada

EE322

Fig

EE 58 Adju ting point gap

Vacuum advance mechanism

Centrifugal

mechanical parts

mechanical parts

If

vacuum

advance mechanism fails

operate properly following items and

check for

to

function 1

as

required

Check

vacuum

leakage 2

correct the mal

or

Check

inlet for signs of

Ifnecessacy

replace with a new one vacuum diaphragm for

air

replace

vacuum

Primary lead termina

2

Ground lead wire

3

Set

4

Adjuster

5

Screw

Inspect breaker plate

moving If pia te does

steel Fig EE 59 Breaker

for smooth

smoothly this condition could be due to sticky steel balls

screw

chanical part

use

balls

breaker

or

or

advance

me

distributor tester

to

See the specifications above When

nothing

is

wrong

conceivable

not move

pivot Apply grease if necessary

plate as an assembly EE 31

part or others disassemble it

to

replace

case

with its

causes are

break down abnormal

In

controller assembly

I

of engine malfunction

centrifugal

driving

If leak is found

EE321

cause

traced to

characteristic

leak

3

When is

check its characteristic

at its connection

retighten

the

advance

wearing out

So

do

of not

of improper characteristic

take off contact breaker assembly and check closely cam assembly governor

weight shaft and governor spring In

case

centrifugal

advance

etc me

chanical part is reassembled be sure to check advance characteristic by dis tributor tester

Engine Electrical System DISASSEMBLY

When breaker plate is removed to lose steel balls not

4

be disassemble

To

proccd

follow the below

ure

head 2

breaker spring and breaker

between

plate

Take off cap and disconnect rotor

I

careful

5

Remove vacuum controller

roll pin

Pul

collar

to

out

remove

and siconnect

the entire rotating

parts

EE075

Fig EE 65 Removing

When governor weight and spring disconnected be careful not to

7 are EE291

Fig EE 60 Removing

stretch

Remove contact set

Refer to Page EE 31

deform governor

After disassembling EE325

3

or

vacuum

controller

cam

governor

spring apply grease

to

weights

Fig EE 63 Removing rollpin when contact

set i removed

ASSEMBLY To assemble

reverse

disassembly Carefully

the order of

observe the fol

lowing instructions are

Align match marls

so

assembled to their

original posi

that parts

tions EE323

Apply grease to assembly as required 2

Fig

EE 61

Removing contact tel EE326

Fig

EE 64 Removil1l rotation paTta

3

EE324

Fig

EE 62 Removing breaker plate

from the top of

Remove

packing

cam

assembly

and

bly

setscrew

Put match mark

earn

and shaft

so

unscrew earn astern across

that original combi

nation can be restored at

EE 32

assembly

cam

Check the operation of governor

before installing distributor

on engine afteT dis timing Adjust ignition tributor is installed on engine

4

6

the top of

Engine Electrical System SERVICE DATA AND SPECIFICATIONS

Type

D4A4 06

D4A4 07

D4A6 07

D4A6 08

42 3

4 2 13

Firing order

1

Rotating direction

Counterclockwise

Counterclockwise

490 to 550

490 to 550

Owen

degree

angle

Point gap

mm

0 45 to 0 55

in

0018

45 0

0 40 to 0 55 0 88 to 121

0 88 to 121

Condenser capacity

JlF

0 20 to 0 24

Condenser isolate resistance

Mrl

5

Cap isolate

resistance

Rotor head isolate resistance mm

Cap carbon point length

55 0

to

0 018 to 0 022

0 022

0 40 to 0 55

lb kg

Point pressure

to

0 20 to 0 24 5

Mrl

50

50

Mrl

50

50

in

10

10

39 0

0 39

For Canada

California models

DISTRIBUTOR

CONTENTS EE 33

ADVANCE MECHANISMS

CONSTRUCTION

EE 33

CHECKING AND ADJUSTMENT

EE 33

DISASSEMBLY

EE 35

EE 33

ASSEMBLY

EE 35

EE 33


EE 36

CAP AIR

AND ROTOR

HEAD

GAP

CONSTRUCTION In the conventional distributor the

ignition liming and breaker

is detected

arm

by the cam

while in this transis

by the reluctor on the shaft and the pick up coil provided in place of the breaker The pick up coil consists of a magnet coil etc The amount of magnetic flux passing through the pole piece in the coil is changed at the moment the pole tor

ignition

unit it is detected

piece faces the protrusion of the re luctor and then the electrical signal is generated in the pick up coil This electric signal is conducted into the transistor

unit which

ignition in turn breaks tI e primary coil current running through the ignition coil and generates high voltage in the secondary winding

Also

this transistor

EE 33

ignition

unit

utilizes

this electric

signal

to

restore the primary coil to the original state after cutting off the primary current

The vance

for

a

fIXed time

centrifugal mechanisms

and

vacuum

employ

ventional mechanical type tactor

is

used

to

eliminate

and centrifugal advance

I

ad

the

con

The

con

vacuum

hysteresis


tl

t3 l

@

1 2

9

3 4

J

@

r 9

V @

fW

Pick up coil

6

Contactoi

7

Breaker

8

Packing

9

Rotor shaft

plate assembly

11

Governor spring Governor weigh t

12 13

Cap

14

Vacuum controller

15 17

Housing Fixing plate O ring

18

Collar

16

@

ReJuctor

S

10

l

Cap assembly Rotor head a55embly Roll pin

Shaft

Jscmbly a

setter

EE327

Fig EE 66 Exploded view of di3tributor

CHECKING AND

assembly and distributor harness their positions

ADJUSTMENT

to

CAP AND ROTOR HEAD

Cap and rotor head must be spected periodically as specified in Maintenance Schedule

in the

Remove cap

and clean all dust and carbon deposits from cap and rotor from time to time If cap is cracked or is leaking replace with

a

new

EE328

Fig EE 67 Checking oir gap

one

To remove

pick

distributor harness and

remove screw

up cail

EE329

disconnect

at terminal block

Fig EE 68

Remouing pick

up coil

securing pick up coil

AIR GAP Standard air gap is 0 2 0 008 to 0 016 in If the

gap

Gap ment

off the

mould

adjustment ening pick

is

to

ADVANCE MECHANISMS 4 mm 0

Specifications standard

be made

up coil screws

gauge

is

D4F4 04

Q3 D4F4

Item

Manual

Automatic

required for adjust

Air gaps must be checked from

Vacuum advance Distributor

time to time Air gap

Type

by loos

0 2 to 0 008

4 0 to

mm

0 016 in

00 150 5 91

degrees

30 250 9 84

Distributor mmHg inHg

Centrifugal

advance

Distributor

degrees

Distributor cpm

EE34

00 550 110 2 300

00 600

1 950 110

Electrical

Engine

System

Vacuum advance mechanism

mechanical parts If vacuum advance mechanism fails to

items and correct the

following lem

prob

required

as

1

check for the

properly

operate

Check

inlet for signs of

vacuum

leakage at its connection If necessary retighten or replace with a new one 2 Check vacuum diaphragm for air

EE075 EE291

leak

Fig EE 69 Removing

If leak is found

replace

Fig

vacuum

EE 72 Removing rotor shaft

controller

vacuum

controller assembly

Inspect breaker plate for smooth moving If plate does not move smoothly this condition could be due to sticky steel balls or pivot Apply grease to steel balls or if necessary replace distributor assembly 3

Remove pick up coil assembly Using two pry bars pry reluctor

3 4

from shaft Be careful

damage

to distort

or

and

Mark

of the governor springs one of the

one

and its bracket Also mark

pivot pins Carefully unhook and remove

10

pin

Remove breaker remove

9

governor weights and its

the teeth of reluctor

Remove roll S

not

plate setscrews breaker plate assembly

governor 11

springs

Remove governor

Apply

grease

to

weights weights

governor

after disassembling

Centrifugal

advance

mechanical parts

engine malfunction centrifugal advance mecha

When cause of is traced to

nical

parts

check

its

use

teristics or

See

characteristics

specifications If nothing

To

to

the

to

above is wrong with its charac

wear

causes are

E330

faulty

of driving part

assem ble

Fig EE 70 Removing breaker plate

or

etscrews

Align match marks so that parts assembled to their original posi

1 are

tions 2

improper character closely rotor shaft assem bly governor weight and shaft

removed

In the event of

If any of above parts

tioning

replace

are

distributor

malfunc

assembly

6

Pull

roll

pin

out

and

7

Remove

rotor

shaft

cam

and

drive

contactor is

If for any reason from breaker

remove

collar

fol

instructions

others So do not disassemble it istics check

the order of

reverse

disassembly Carefully observe the

lowing

conceivable

abnormal

tester

distributor

ASSEMBLY

plate adjust

clearance to

contactor to

0 012 in

as

3 mm 0

shown in Figure EE 73

after installation

shaft assembly

T DISASSEMBLY To

disassemble

follow the

pro EE298

cedure below 1

Take

off cap and

Fig EE 73 Cam remove

rotor

head 2

Fig EE 71 Remove

two

screws

Figure EE 69 and detach troller

contactor to

EE331

shown in

shaft and drive shaft assembly

Removing

clearance

rotor

vacuum con

3

Ensure that reluctor is

orien ted when

8

Mark rotor shaft and drive shaft Remove

rotor

shaft

packing from and

unscrew

setscrew EE 35

the

top of

rotor

shaft

installing

Always drive toward

in roll

the outer end

Figure EE 74 pin

on

properly

shaft

pin with

its slit

of shaft See

Be sure to use

a

new

roll

Engine Electrical System 4

Apply grease to the top of rotor shaft as required 5 Check the operation of governor before installing distributor on engine 6 Adjust ignition timing after distri butor is installed on engine

EE299

Fig EE 74 Driving in rollpin

SERVICE DATA AND SPECIFICATIONS Type Firing

D4F4 03 order

1

04 D4F4

4 2 3

Rotating direction

Counterclockwise

Duty

70 20 to 40 at

Air gap

mm

0 2 to 0 4 O OOS to 0 016

MU

More than 50

Rotor head insulation resistance MU

More than 50

Cap insulation

Cap

resistance

in

carbon point length

mm

idling

in

10

TRANSISTOR IGNITION UNIT

39 0

California models


EE 36

TRANSISTOR REMOVAL AND

IGNITION

POWER

CONTINUITY CHECK OF PRIMARY

EE 37

3

PICK UP COIL

CONTINUITY CHECK

EE 37

4

PICK UP COIL

POWER

EE 36

INSTALLATION

INSPECTION 1

2

UNIT

CIRCUIT

SUPPLY WI RING AND

BATTERY

PULSE

CHECK

EE 37

5

EE 36 EE 38

SIGNAL EE 38

CHECK

TRANSISTOR

IGNITION

UNIT

CHECK

EE 39

DESCRIPTION TRANSISTOR

IGNITION

UNIT the L

The transistor ignition unit provides following functions It makes and breaks

current in the

ignition coil

primacy

the electric

circuit of the

is

provided

This

cuts

off the

The duty control circuit sets the rate of make and break within one

ing

cycle ie

this maintains good ignition characteristics of engine from low

coil when the ignition switch is turned

high speed and is equal to dweU angle in the conventional

Each component part of this unit is

2

speed the

to

breaker type distributor 3

A

preventive

circuit

EE 36

against lock

prilnaCY on

electric current in the

ignition

with the engine not running

highly reliable

however

should any

part be found faulty the entire bly must be replaced

assem

Engine Electrical System The items are classified by numerals in Transistor ignition unit

accordance with the objective of

checks

to

diagrams 45 EE

be performed Several wiring found on pages 41 to EE

are

The

Power

r1

Duty control circuit

switching circuit

1

Spark timing Signal mom toring circuit

Lock

1

circuit

each

When checking

oscilloscope careful not

or to

To distributor

Also

circuit

Distributor

result

Ignition coil

EE437

do

not

attempt to

Fig EE 75 Transistor ignition unit circuit diagram

damage

to

oscilloscope

INSPECTION

ignition

unit is located

panel

in

2

Disconnect wiring harness

from

Remove

3

move

4

two

setscrews

and

te

unit

for

To install

reverse

the order of

to

their

Failure to do

so

wiring

har

proper positio will damage the

unit

Refer to

Figure

if

and

tension wires for

make

or a

performance

an

circuit tester

checks

and adjust gaps

spark plugs

use

necessary

ignition oscilloscope

Replace

a

tachometer with

parallel

or an

circuit tester is al

provided that such

a

connec

wiring

connections

checks

use

as neces

not

If the above

the problem ignition system with

cannot correct

check the entire

oscilloscope

or

a

POWER SUPPLY WIRING

1

AND BAnERY CHECK

See wIrIng diagram In

FIgure

EE 88

Check

spark plug which is

suitable for further

an

EE 76

a

a

distributor

sary

Be sure to connect

nesses

cracked

a

cap and corroded tenninals

or

Visually inspect high

to

removal Note

rotor

condition

unit

or

in

tion system as follows

Check

Disconnect battery negative

transistor

tion is made with due consideration to

If the engine does not run due to faulty ignition system check the igni

passenger compartment cable

the

circuit tester

or

lowable

designated

unit as well as to the oscillo

timing light

a

con

in the

points

those

The connection of

the right hand dash side

be

of the lead wires will

handling

in

ignition scope

Transistor

an

potential difference

other than

Careless

on

tester

confuse the polarity of

nect the lead wires to any

nm


circuit with

circuit

between

tacted

ttery

the item

the check points at which the lead wires are to be con exists

Ba

a

a

the lead wires if To starter

individual

check

j

preven ling

thick lines indicate

of

objective

Procedure I

Turn on

2

Connect

oscilloscope

ignition switch a as

circuit

tester

or

an

shown in the

figure

DC

range

below

circuit tester

CHECKING WITH AN OSCILLOSCOPE L

An

oscilloscope

can

checking almost all transistor

be used for

the items in

a

ignition system

CHECKING WITH A CIRCUIT

EE302

TESTER A circuit tester the duty Fig EE 76 External view of ignition unit

t18nsistor methods circuit

50 volt

can

not be used for

Fig EE 77 Checking power supply wiring and batt ry

control circuit and power

performance use

tester

of

an

are

tests

oscilloscope

Both and

a

described in this

section

Criterion When power source voltage is indicated

battery

Lower or no indication

EE 37

OK N G

Engine Electrical System If the result is

following I

N C

Check

BW

Check

and

an

B

proper

con

3

low

for

voltage

Check resistor and ignition coil

for

Resistance 10 range

discontinuity

4

Check

WB

color wire harness

of ignition coil assembly for proper

of bat

condition

Check resistor and ignition coil

terminals for loose contact

con

terminals

excessively

2

color wire

for proper

battery

proper connection Check charge 3

tery if

respectively for

ductance

harness respectively ductance 2

harness

Take the

measures

fp

continuity

is

EE305

indicated 2 2

Chacklng IgnitIon coil auembly See wiring

Fig

EE BO

Checking pick

up

coil

Criterion

diagram In Fig EE 90

When approximately 720 ohm

Procedure

is indicated

I

Far less than

Disconnect ignition coil and dis

tributor

2

2

PRIMARY CIRCUIT

Connect

in the

CheckIng

circuit

from

a

N C

If the result is

circuit tester as shown

pick

figure below

up coil

N C

Replace

assembly

prImary

89 EE

Resistance 1 range

Disconnect

PICK UP COIL POWER

L

Q

color wire from

Procedure

fD o

unit

2

Turn

3

C ooneet

on

oscilloscope

4

SIGNAL PULSE CHECK

Proced ure

ignition

720 ohm

ignition coil

See wiring diagram

In Fig

I

than

external resistor

CONTINUITY CHECK OF

2 1

harness

OK or more

ignition switch

as

a

cireui t

tester

or

I Disconnect anti dieseling solenoid

ro

an

shown in Figure EE 78

valve connector 2 EE336

Fig EE 79

Checking ignition coil

Connect

in the

figure

a


below

3

Rotate starter motor

4

Read the tester indication

assembly

DC 50volt range

Criterion

S tf

When approximately 1 6 to 2 0 ohm is indicated

Fig

ignition

EE 78 Checking primary circuit

3

N C

EE306

When Donnal power

battery voltage or no

Source

is indicated

indication

Fig EE 81 Checking pick

PICK UP COIL

wirIng dIagram Figure EE

up

coil power

aignal pulse

See

In

Criterion

91

When pointer deflects

OK N G

range

Replace

assembly

CONTINUITY CHECK

Criterion

Lower

coil

volt S

N C

EE303

If the result is

AC 2

OK

More than 2 0 ohm

slightly

Procedure

OK

When pointer does not deflect If the result is

N C

Disconnect

Take the

following measures

wires from

2 1

Check

BW

and

L

color wire

ignition

Connect

in the

R

figure

a

and

G

color

at all

N C

unit

circuit tester

below

EE 3B

as

shown

If the result is

pick up coil assembly

N C

Replace

Electrical

Engine Procedure

with

an

oscilloscope

valve connector 2

Connect

positive lead of

a

oscilloscope negative lead

oscilloscope

an

Set

3

o

to

to the

oscilloscope

an

select switch of

SLOPE

a

positive side

Rotate starter motor

5

Check the

wave

form

as

0 C

EB

80

shown in

figure below

the

8 r

0

EB

If

equipped

4

8W

a

color wire

G

so

of

Oscilloscope

an

olor wire and

R

to

terminal

Ignition coil

dieseling solenoid

Disconnect anti

1

System

To body metal EE307

Fig EE 83 Checking operation of transistor ignition unit

EE268

Fig EE 82 Wave form ofpick

up

coil

@

Criterion When the the

wave

shape of

When the

shape

of

there is

a

form takes

full line

wave

dashed line

a

OK

form takes the or

when

@

N G

form

no wave

EE452

If the result is

N G

Replace Fig EE 84 W uve form ofpulse

pick

up coil

5

TRANSISTOR IGNITION

assembly

UNIT CHECK

See wiring

Check items 5 1 and

Connect

ignition

with an

oscilloscope Where an

oscilloscope

ble check to make ous

tests

satisfactory and that no issuing from the secondary

the

part

wire

Replace

After replacement

sparks from the secondary

cord

Checking operatIon

coil

and

dis

tributor harness to ignition coil exter nal resistor

shown in

rotate the starter motor wave

form

the

on

1

Connect

ignition

tributor harness

to

coil and

ignition coil

dis

exter

nal resistor 2

oscilloscope

Connect wiring harness

to

igni

tion unit 3

Disconnect anti dieseling solenoid

valve connector 4

Criterion

away

See Figure EE 84 When a

a

the

Keep

secondary high

wire end 4 to 5 mm

starter

form similar

wave

to

a

wave

or

0 16

engine block

motor across

and

to

tension

0 20 in

rotate the

check

whether

the clearance

OK form similar to b

when

no

wave

is

form is N G

N G

the fault lies

either in the transistor unit or in the

secondary high

from

sparks fly

is observed

If the result is

ignition

as

observed

Procedure Connect

Procedure

and observe the

obseIVed

of transIstor Ignition unit

I

EE 83

When

5 1

avail

not

solenoid

satisfactory

ignition unit is discontinuity in the

faulty

check the

is

transistor

faulty or there is secondary high tension the

previ

are

spark is high tension wire If everything else then

is not availa that all

sure

dieseling

Connect oscilloscope

Figure

oscilloscope is

an

able

unit

valve connector 4

If

the

to

harness

wiring

Disconnect anti

3

diagram In Figure EE 92 5 2

2

tension wire

Replace these parts EE 39

Criterion OK

Where sparks issue Where

no

spark

N G

issues

N G the fault If the result is lies either in the transistor unit or in

secondary high tension Replace these paris

the

wire

Engine Electrical System 5 2

Checking operation

of duty

DC

Procedure Connect

anti

While the

fJ

O

BW tor Transi

L

valve connector 2

B

rC

solenoid

dieseling

50 volt range

ignition

o

engine

the

wave

ronn

the

same

way as

on

is

idling

t 1

observe

8

the oscilloscope in

V

stated in item 5 the ratio

Figure EE 83 Determine as shown in Figure EE 85

unit

tiT

I x

T

100

20 to at

1 401 EE357

idling Fig EE 86 Checking lock p

h

1 Lt

T

Criterion

tion in the

When power is indicated When

EE257

source

Figure

voltage OK

approximately

zero

is indicated

Fig EE 85 Wove form ofduty pulse

following Criterion When

a

measures

Replace is obtaiiied

less than 20

If

OK

When the ratio obtained is

transistor

form

on

an

N G

If the result is

to

whether the

wave

oscilloscope rises source voltage within

up to about

see

after

ignition switch

is

on

ignition unit

When

I

Criterion using

ignition

N G

an

oscilloscope

in

arrange the connec

The use

of

same a

as

described before for

tester

Replace

unit

5 3 Checking lock preventive circuit a

Turn

oscilloScope is uSetl

stead of a tester

If

Figure

shown in

86 EE

the

the power 10 seconds turned

Procedure

or

than 40

transistor

Take the

way as

standard ratio of about

20 to 40

more

N G

or

ignition switch

Check

voltage N G

If the result is

on

same

EE 83

uentive circuit

Power

source

voltage

circuit tester is used

Oy

Procedure 1

Connect

a

t


in

83 EE or EE Figure 86 positive terminal of tester is connected to L color

Ignition switch ON EE430

wire and

negative terminal of tester is grounded 2 Turn on ignition switch Check to see

Fig EE 87 Wave form of lock preventive circuit

whether the tester indicates the

volage

of

as soon as

power

source

ignition switch

ba t1ery

is turned on

40 EE

l1

5 l1

rn

1 Al13

n

c

E438

E

bat e

c

and r I

y 1

control

switching

Duty circuit

Power dtCuit

er

PO

19niton

prev nti g

o

timing

uPP

unit

lonltoriOi l 1

sign

t

sparlt circui

oClt

l

item for

cl cuit

ram l8 di

Wiring 88

P

EE

am c s

Fill

Harne L

llW

II

R

G

oC

r

b

Terminal auemblY coil BR

tC l

nitonS

IgnitOn o

It

11

Utstnot i

rn llO

3D

l WC

0c

f

3

439

0

eE

con o

switcnlOS

unit

DUtY circuit

powet cucuil

lng

o

on nit 19

monitrng cltCuit Itev nti s circuit

tiR

K Loc

w

1

Spade oIgn alnP c o

Il

IlW

Harnes

L R G

r

k OC

b

Terminal asemblY

coil

igniton

IlR

o

Wb

DistrbuO

rn l0

r

Wo

l IlS3

O

blY

EeA40 ncoi1 0 1

ing tdl

cont o

Iln1 i

unit

putY ciIcuit

sVI

rowel citCuit

nll R

Igniton

CMC 2

2

ptel nu t

oth1

o

t

tunin tnoo

for

cirCuit

K lflc

a sign

atK

ite

citcuit

S1

dioS

Wirinl clarnp @

90

EE

rnesS

Fig

a H

L

ll

R

G

B

OC

r

o

ina

let1 uW

auefC coll P iUO

19t

llR

Dutot tri

sWitch

o

O gn1t10

b

I Iu 5 l

l

ll l

01Il

f

EE44 o

o

lTcofO l unl

swilchln

DUtY tCU

o1 l

C

powet CltCU1l

tn

o

preyen

onitoifl

t titrllt

tl

l

St

signacircuit

f

LOCK circuit

cump @

e

Ratt I

BW

B

l

G

blocK

r

oa

Ter n rntM

I

a

CO

Of

l ll t

f1

bUlot o Witch s

on

gni

Wt

OliU

El19ine

l

svstel O

ElectriCal

it

j

g j

15

0

i

l 0

5

l

J

i

CI

g

C

e

0

t 0

t

l

l

2

0

l

a a e t ll

I

t

l

S

1

ll

1

u

oJ

ll

foil

i i 0

t

a

e 0 u

0

S

r

e

CD

a

0

0

4S EE


IGNITION COIL The ignition

coil is

type

with oil which has good heat

radiating

oil f1l1ed

an

The ignition coil

case

California models

califomia Non

filled

is

insulating

models

and

characteristics

The ignition coil has a greater ratio between the primary and secondary

windings

step up battery voltage t voltage This causes stronger sparks to jump the spark plug gap to

The which

cap

is made of

offers high

alkyd

resistance to

ID

f

high

@

resin

J

lectric

C

arc and increased insulation

ID

The ignition coil and resistor should as a matched set

be handled When

high

ignition coil

to

there should be

1W

I

tension wire is installed no

clearance between their caps

EE314

1 2 3 4 5 6 7

R

bber cap for ignition coil Secondary terminal

8 9

Cap Primary terminal Spring Secondary winding Primary winding

Fig

Side

core

Insulator coil

10

Center

11

Segment

12

Case

13

Rubber cap Cor terminal

core

EE 93 Sectional view of ignition coil

Notes a

Do

disconnect

high tension spark plugs during en California models gine mnning only RoD up high tension wire mbber cap and instaD high tension wire to ignition coil securely Refer to Figure EE9S not

wires from

I

Fig

EE354

1

High tension wire

2

Rubber cap

b

EE 94 Correcl installation of high t Mjon win

Fig EE 95 Installing high tension wire

SPECIFICATIONS Non California California models

models

Type

618 C6R

Primary voltage

V

Spark

mm

gap

Primary resistance Secondary

at

200C 680F

resistance at

200C 680 F

External resistor at20 C

680F

HS 15 18

12 in

more

CIT 16 STC 9

12 than 7

0 28

more

than 7 0 28

n

108 to 1 32

45 0

KSl

8 24 to

5 to 12 7 8

n

5 1 46 EE

4 12

3 1

to

4 0

55 0

09

Electrical

Engine

System

SPARK PLUG CONTENTS

TROUBLE

EE 47

INSPECTION CLEANING AND REGAP

White

Overheating

light gray

or

in

sulator with black gray brown bluish burnt electrodes spots and or

The spark plugs tional type

spark plug

and 0 8

models

0 031 to 0 035 in

indicate engine overheating More over the appearance results from

1 0 to

are

Cali

on

timing

ignition

incorrect 09

to

on non

conven

0 551 in

gaps 0 039 to 0 043 in

1 mm

fomia

of the

14 mm

having

The

threads

are

4B EE

CORRECTIONS

47 EE

DESCRIPTION

EE 4B

SERVICE DATA AND SPECIFICATIONS DIAGNOSES AND

47 EE

DESCRIPTION

mm

spark plugs

low fuel pump pres of fuel a

wrong selection

sure

hotter

plug

etc

It is advisable to

having

replace

with

plugs

colder heat range

loose

California

The inspection and cleaning should be made every suitable mainte models

If necessary

period

nance

All spark

Note

installed

plugs

Ir

replace on

i

an

must be of the same brand

engine

and the

number of heat range

same

Carbon fould

Normal

INSPECTION L

Remove

pulling

on

plug

spark

by

wire

not on wire itself

boot

2

Remove

3

Check electrodes and inner and

spark plugs

porcelains of plugs noting the deposits and the degree of type electrode erosion Refer to Figure outer

of

Worn

Overheating

Fig EE 96 Spark plug

EE079

EE96 Normal

posits

and

indicate

spark

de

tan

electrode

slight

correct

wear

heat

plug

carbon

Dry

fluffy

the

insulator

on

and

usually caused by slow speed driving in city weak electrode

are

ignition too rich fuel dirty air cleaner etc

replace

It is advisable to

mixture

excessive

oil

entrance

into

combustion chamber through

worn

rings and pistons ance

between

stems

If the

mains

after

plug

a

or

excessive clear

valve same

repair

guides and condition use

a

electrodes

smaU fine file to flatten the of

both

center

and

side

parallel Set spark plug to specification gap 5 InstaU spark plugs and torque each plug to L5 to 2 0 kg m 11 to 14 electwdes

in

ft Ib Connect spark

plug

discard

plugs cleaning spark plugs

After

renew

firing surface of electrodes with me mentioned aboVe Then gap spark

plugs

to

specified

wire feeler gauge

values with All

a

round

spark plugs

new

or used should have the gap checked and reset by bending ground electrode

wires

plugs

having hotter heat range Oil fouled Wet black deposits indi cate

with

6 with

dress

After cleaning

4

surfaces

range Carbon fouled

deposits

grayish

to

Brown

re

hotter

CLEANING AND REGAP Clean

spark plugs

in a sand blast

type cleaner Avoid excessive blasting Clean and remove carbon or oxide

deposits porcelain

but

do

If deposits

47 EE

not are

wear

away

too stubborn

EEOBO

Fig EE 97 Setting park plug gap

Engine Electrical System SERVICE DATA AND SPECIFICATIONS Non California models

California models

Standard

Hot type

Type

Cold type

BP6ES ll

BP6ES

L45PW ll

L45PW

BP4E ll BP5ES ll

BP4E BP5ES

BPR4ES

L46PW ll L47PW ll

L46PW L47PW

BPR5ES

BP7ES ll

BP7ES

LMPW ll

LMPW

10 to l

Plug gap

mm

Tightening torque

kg

in

m

ft Ib

For Canada

except for Canada

BPR6ES

BPR7ES

0 8 to 0 9

0 039 to 0 043

0 031 to

I

5 to 2 1

11 0

0 8 to 0 9 0 031 to 0 035

D35 0 to 14

TROUBLE DIAGNOSES AND CORRECTIONS Note When engine does not start If there system

is

no

ignition

checked

detaching

This a

can

high

problem

should

system be

spark

at all

fuel be

easily done by

tension

wire from

Condition

No

in

spark plug starting engine and ob serving condition of spark that occurs between high tension wire and spark plug terminal After checking this repair as necessary

Location

Distributor

Probable

On California models

nect

anti

dieseling

discon

solenoid

valve

connector to cut off supply of fuel to

and

engine

then

condition

of

motor is in

operation

spaIks

observe

Corrective action

cause

Faulty insulation of condenser Non Cali

Replace

fomia models

Breakage of lead wire

on

low tension side

Repair

Poor insulation of cap and rotor head

Replace

Seized points Non California models

Repair

Open pick Air

gap

up coil

California models

wider than

specification

Replace Cali

Adjust

fornia models

Ignition coil

Wire

High

Wire coming off

tension wire

breakage

Faulty Transistor ignition unit California

or

short circuit of coil

Repair

insulation

Faulty transistor ignition

models

4B EE

Replace

Replace unit

Replace

the

while starter

with

new one


Probable

Location

Condition

Point gap too wide

Distributor

Spark length

Corrective action

cause

California Non

mo

Correct

dels

I to 2 rnm 0 039

models

Clean

to 0 079 in Of

Oil

irregular

Burned points Non California models

Replace

Spark plug gap too wide

Correct

Too much carbon

Clean

Broken neck of insulator

Replace

Expiration of plug life

Replace

Spark plugs

More than 6 rnm

0 236 in

point

on

California Non

California models

Distributor

Air gap too wide

Transistor ignition unit California


or

or

replace

replace

Correct

Replace

unit

models

2

Engine smoothly

rotates but does not

This may be caused

misses

system

or

complete inspection of ignition system

other engine condi Hons not Therefore first a

should be carried out

related to ignition

by

the

ignition Probable

Location

Condition

Engine

run

Distributor

Corrective ac ion

cause

Clean

Dirty point Non California models Foreign

pick

mattef on

up coil

California

Clean

models Non California

Improper point gap

mo

Correct

dels

Impropef

California models

air gap

Correct

Leak of electricity at cap and rotor head

Damaged

insulation of condenser

Non

Repair

or

replace

Replace

California models

Malfunctioning

arm

Non Cali

Oil shaft

spring

Non Cali

Replace

contact

fornia models

Faulty

contact

arm

fornia models

Breakage

of lead

wire

Non California

Replace

models

Breakage

of pick up coil lead wire Cali

Replace

fornia models

Ignition coil

Worn

or

shaky breaker plate

Replace assembly

Worn

or

shaky distributor driving shaft

Replace assembly

Layer short circuit

or

inferior

quality

Replace

coil

High

tension wire

Deterioration

of

insulation

sequent leak of electricity

49 EE

with

con

Replace

with

good

one


Condition

Location

Spark plugs

Probable

cause

Corrective action

Fouled

Clean

Leak of

electricity

at

upper

porcelain

Repair

or

replace

insulator Transistor ignition


unit

Replace

unit California

models

Engine causes knocking very

Distributor

Improper ignition timing Coming

often

off

or

too advanced

of governor

breakage

Correct Correct or

replace

spring Worn pin

Engine

does not

or

hole of governor

Spark plugs

Burnt too much

Distributor


deliver enough

Replace

Improper functioning

power

Point gap models

too

Replace

too retarded

Replace assembly

governor

narrow

Foreign particles stuck

Non California

in air gap

Correct

Cali

Correct

Oean

fornia models

Spark plugs

Fouled

EE 50

Oean

SECTION ER

ENGINE DATSUN PICK UP MODEL 620 SERIES

REMOVAL INSTALLATION

ENGINE REMOVAL AND INSTALLATION


LTD JAPAN

ER

2

Removal

Engine

Installation

ENGINE REMOVAL AND INSTAllATION CONTENTS REMOVAL

ER 2

FRONT

INSTALLATION

ER 3

REAR INSULATOR

INSULATORS

ENGINE MOUNTING

ER 3

REMOVAL

INSULATOR

TIGHTENING

Disconnect air deaner

to A

4 ER 4 ER

TORQUE

4 ER

B valve

hose It is much easier to

engine single unit than to remove them separately After re moval engine can be separated from transntission assembly and transmission

remove

air

Disconnect

a

as

cleaner ta

vacuum

hoses

Note

Protect

and

foreign

over

carburetor from dust matter

by placing

cover

air inlet opening

Notes a

Be sure to hoist

transmission in b

engine and jack

Fig ER

up

l

a safe manner

Use fender

cove to


protect vehicle I

body

Disconnect selector range lever

from manual shaft 1

Remove

2

Scribe

9

battery hinge

hood

location for

reinstallation

proper hood

and

remove

to

prevent damage

to

help

you

so as

14

Disconnect carbon canister hose

engine side Disconnect

C1eaner 12

body

to

al

air

pump

air

Drain radiator coolant

4

Disconnect

and upper radiator hoses from engine

lower

5

Remove

hoses

from lower matic

two

oil

cooler

Disconnect

following

cables

end of radiator

transmission models

only

to

ignition

Remove radiator shroud

7

Remove four bolts securing radia

body

ter

Wires

to

B C

p

D

Non California Note

Always tighten securing bolt at upper right hand side together with body harness terminal

Remove carburetor air cleaner

solenoid

cut

models

autochoke heater and anti

only

dieseling

solenoid

as

follows

cover

hose

air at

cleaner to rocker

rocker

Disconnect air cleaner to air control valve hose

California models

only

securing and flexi

16

Disconnect

transmission

control

from transmission

Manual transmission models Detach rubber boot Remove E ring and control lever from transmission striking rod and remove control lever

ER 2

Manual

front exhaust tube

from exhaust manifold 17

2

3

lamp switch

Cable to speedometer

pin guide

bolts

operating cylinder as an assembly transmission models only

Remove

propeller shaft propeller bearing bracket from

Disconnect

Disconnect

carrier

2

cover

two

tube

companion

Remove

of

Then dis

Vacuum hose of Master Vac at in

I

hoses

vacuum

Remove

equipped

linkage

se

com

clutch operating cylinder

crossmember

13

the

move

Remove F LC D actuator

Wires to starter motor

Wires for back up

Disconnect

3

center

Remove hot air duct

hose

ressor comi

battery support

Wires to alternator

taJce manifold

Loosen air cleaner band bolt and air

Then

Remove

I

Remove fresh air duct

cleaner supporting bolts Disconnect air cleaner ta air pump hose

curing bolts

ble

Heater inlet and outlet hoses if so 8

flexible

connect

Wire to oil pressure switch Wires to thermal transmitter

tor and detach radiator

removing four

After

15

distributor at

minal

6

1

F LC D solenoid valve

coil and distributor

Wire

equipped


2

Accelerator wire at carburetor

Auto

conditioner

models need

pressor to

tension cable between

inhibitor

at

remove support

Engine ground cable High

Air

p hose

p

wires and hoses

3

wires

10

II

assistant

an

Disconnect

switch and down shift solenoid

on

Have

Note

2

Disconnect fuel pump to fuel fdter hose and return hose

propeller flange of

Remove

propeller

shaft third

shaft from differential

shaft

from

transmission

and plug up rear end of extension housing of transmission to

prevent oil leakage 18

Attach

to lift

engine

19

Remove

a

suitable wire

or

chain

front engine mounting

bolts at engine mounting front sup

port

Installation

Engine Removal

ER207

Fig ER 2 Removing front engine mounting bolts Place

20

a

jack under

transmission

and jack it up Loosen two rear

21

engine

mount

E

ing bolts CD

Fig ER 5 Lifting engine

Loosen two exhaust tube

hanger bolts V California models only 23 Remove four bolts CID securing engine mounting rear support to side 22

member and detach

rear

INSTALLATION

support

Install engine with transmission in reverse

order of removal

observing

the

O

jr

R367

following When

I

installing

first

secure

engine mounting support to body 2 Refer to applicable section when installing and adjusting any parts

rear

2

1 ER271

Removing

Fig ER 3

rear

engine

mounting support 24

Remove steering idler arm secur ing bolts and push down cross rod

Front

1

Bracket RH

2

Insulator R H

3

Bracket LH

4

Heat shield plate Insulator L H

5

iC

@

6 7

Rear

8

Exhaust tube hanger California models only

support

Rear insulator E

A279

Fig ER 6 Structual view of engine mounting

EA278

Fig ER 4 Removing idler

Pull engine towards front as far and carefully raise if and

25 as

arm

possible

transmission with

a

hoist and cable

ENGINE

MOUNTING

INSULATORS Three insulators

Note

In this

an r

always be taken unit

parts

to

hit

not

against

care

should

to allow the any

adjacent

the engine

are

used

and transmission

to

Replace

mount

two are

located at the left and right of the at the transmis

cylinder block and

one

sion rear extension

housing

ER 3

any

insulator that shows

signs of separation Be oil

or

sure

to

grease

or

deterioration

keep insulator free from

Engine Removal FRONT

INSULATOR

7

To

install

Installation

reverse

order of

re

moval Removal and installation

and jack it up slightly 2 Loosen two rear engine mounting bolts 3

1

Disconnect battery ground cable

2

Remove hood

3

Suspend

with

engine

wire

REAR INSULATOR

or

Loosen front

engine mounting

insulator upper nuts

both

5

Carefully

engine

a

hoist and cable

6

Remove

raise

Loosen two exhaust tube hanger California models only

4

Remove

at

chain 4

bolts

a

mounting

rear

removing insulator securing bolts

1

moval

little with

Place

a

jack under

transmission

To

install

reverse

front

mounting insula supports after removing front mounting bolts tors at front

TIGHTENING Fixing

TORQUE

bolts and nuts

Front mounting bracket to cylinder block

kg

ft lb

2 6 to 3 6 19 to 26

Front mounting in

kg m

ft Ib

2 6 to 3 6

Front mounting insulator to front support

kg

m

ft lb

14 to 18

10 to 13

Rear

mounting

kg

m

ft lb

3 2 to 3 7

23 to 27

Rear

mounting insulator

kg m

ft Ib

16 to 2 2

Rear

support to frame

kg m

ft lb

3 2 to

Clutch operating cylinder to transmission

kg m

ft Io

2 5 to 3 5

Exhaust front tube to exhaust manifold

kg m

ft lb

19 to 2 5

14 to 18

Center

bracket to crossrnember

kg m

ft lb

16 to 2 2

12 to 16

to

kg m

ft lb

2 4 to

bearing

Propeller shaft

lator to brac

t

insulator to transmission to rear

support

companion flange

insulator

extension after

Ramoval and Installation

5

sides

rear

transmission

m

4 ER

19

12

to

76

to 16

3 23 to 31 4

18

to 25

3 17 to 24

order

of

Ie

SECTION CL

CLUTCH DATSUN PICK UP MODEL 620 SERIES

LNISSAN I NISSAN MOTOR CO TOKYO

LTD JAPAN

CLUTCH

CL

2

CLUTCH CONTROL

CL

5


CL 9


CLIO


CL12

CLUTCH

CLUTCH CONTENTS CL 3


DESCRIPTION

CL 2

REMOVAL AND INSTAllATION

Cl2

D isassemb I y

Cl3

CL 2

Assembly

CL 3

CL 3

INSPECTION

CL 4

Removal Installation

DESCRIPTION The clutch is

using the

single dry disc type

a

a

diaphragm spring

clutch

disc

It consists of dia

plate

pressure

phragm spring cover I

thrust

clutch

rings

and clutch release bearing

A

u

o

e M 0

8

s

62 2 44

o

8

dia

6

l150 225

91 dia 8 86 dia

I

5

260 10 2

o

dia CL231

C Unit

Fig CL

portant

REMOVAL AND

disc

NSTALLATIO CL 2

I

3

Removal Remove

1

from

ve

hicle For details oftransmission removal refer to 2

Construction of clutch disc and

six

Loosen

screws

assembly

attaching

time each

flywheel one turn at a is re un til spring pressure

leased

sure

cover

Be

COller

in

support weight of clutch further steps See Figure

to

during

clutch transmission

l

mm

to

to turn them out in

a

crisscross fashion

Transmission Section

Insert

KV30100200 until it will

Clutch into no

Aligning clutch

longer

go

Bar

Note

special care to on getting on

Exercise

disc hub

grease

It is im

linings

or

avoid clutch

Fig CL2

CL 2

Supporting

clutch assembly

CLUTCH Installation

diaphragm spring is securely reveted to clutch cover and clutch cover assembly is balanced If necessary replace clutch cover disassembled since

Apply a light coat of lithium base containing molybdenum disul

I

grease

phide

transmission main drive gear

on

assembly

splines

wipe off excess lubricant pushed by disc hub Install

2

cover

clutch

assembly

disc

off

flywheel Support

on

as

two assemblies with Clutch Aligning Bar KV30100200 See Figure CL 3

follows See Figure CL4

Remove 1 houisng 2

clutch

and

Be

to

sure

from clutch

cover

CLOSS

withdrawal lever from

CL 6 Removing pilot bu hing

Fig

clutch housing 3

Remove

retainer

from

spring

withdrawal lever Remove release bearing bearing

Asse

1

housing

on

as an

assembly 1

7 1

bly

Release mechaniam

sleeve and holder spring from clu tch

00

R

dust

Remove

4

keep disc facings and flywheel pressure plate clean and dry

Note

complete unit

as a

Remove clutch release mechanism

2

Slide clutch disc on main drive gear several times Remove clutch disc and

When assembling release sleeve

squarely

use a

on

J

I

I

Release bearing Release

1

bearing

sleeve

rr Fig CL 3

CL109

l talling clutch

cover

assem

3

Holder spring

4

Dust

5

Withdrawal

6

Retainer

bly

J

cover

lever

spring

assembly

Each bolt turn at

a

should be

cover

Remove

KV30100200

tightened one specified torque

II to 16 ft Ib

m

Three dowels

clutch 4

flywheel squarely

time to the

15 to 2 2 kg Note

to

on

are

Fig CL 7 1

CL119

Fig CL4 Exploded view ofclutch

Install six bolts to tighten clutch

cover

2

Take

out

clutch release

from bearing sleeve

puller

See

using

a

Before

bricate

light 3

CL215

1

releaae mechaniam

3

bearing bearing

sleeve See Figure CL 7

l

lo

2

press and seat

e bearing rele

during assembling lu following points with a

or

the coat

tailing

of

multi purpose grease

bearing

universal

Figure CL 5

I

Inner groove of release bearing 8 CL

sleeve See Figure

used to locate

flywheel properly Aligning

Bar

tightening

the

Clutch after

Lf

bolts securely 5

Install transmission

Note

Make certain

that withdrawal

lever engages lever ball pin I

6

n

Connect

push rod of clutch op erating cylinder to withdrawal lever D

embling

e rele

b


I

Clutch cover

assembly

4

Remove

by

ST16610001 can

not be

aring

CL216

Fig CL B Lu bricating

bearing

shaft

Disassembly

JQt

C L014

Fig CL 5

pilot bushing Pilot

in crank

Bushing

if necessary See

6 CL

Puller

Figure

2

of

Contact surfaces of withdrawal

lever lever ball pin and bearing sleeve 3 Contact surfaces of transmission front

CL3

ee

slee

cover

See

Figure

CL 9

CLUTCH If facings

I

be

lt

oily the disc should

cover rear

oil

I

Lubricating poinu of

trans

pilot

seal

oil seals and other

points for oil leakage 2 The disc should also be

CUll

CL 9

front

bushing engine

o

Fig

replaced

mission

tJ

P

are

In this case inspect

If excessive clutch

Measure the

2

spring

front

Place

a

of

Contact surfaces

then on

main drive gear

splines lithium base including molybdenum disul

grease

phide

clutch

assembly

plate by using

Set Bolls

tighten

the base

Very IIIIJllII

amount

should

be

points applied

If too much

friction

plates

in d

ated

it will

gi

to

run

1 t

vernier

iubricant

at several

caliper depth

f

drawal

lever

is

to

with

Fit holder

f Fig CL I0

ever

then

4

assemble withdrawal Iever and

install dust

the old

plate for

7

disc

or

C L23

new

one

STl005Q051 CL 12

Fig

runout when

a

05001O

uring the height of Me diaphragm pring

is

installed If runoutexceeds the

Install this

value

at

Then

place

or

case

lining

JIuringclutch Me

Check disc

3

spring to release bearing and sleeve assembly

bearing sleeve as a unit assembly on transmission

Tl

CL089

resulting facings

Install retainer spring

I

rJrf

when hot

dutch disc

gauge

STl0050100

the

on

spring toe points with a

diaphragm A

height

of grease the above

out

and

cover

Above 0 3 rom 10 012 in

Note

3

i h

1

j1

Figure

Plate ST20050010

b Measure

II

gauge

See

ST20050051

I

l

DePth

transmission

height of diaphragm

Distance Piece ST20050100

Base

on

See Figure CL IO

cover

assembly

outlined below

as

replace

replaced

withdrawal lever and

4

is found

CL 12

when facings are worn locally or worn 0 mm 0 0118 in at down less than 3 revels

wear

cover as an

cover

the outer circumference

Ie

repair disc See Figure CLII

5 0

Pilot bushing

installing a new bushing thoroughly clean bushing hole Install bushing in crankshaft using a soft hammer Bushing need not be oiled

mm

reading

ST20050240

See

Figure

If necessary

replace

clutch

cover as

assembly Also unevenness of dia phragm spring toe height should be an

4 23 in

mm

in

adjust the spring Diaphragm Adjusting

with

CL 13

R from the hub center

5 107

123 to 1 38

Wrench

0020 in

mm

total indicator

Before

beyond the

height

Runou t

of spring end is A value of 33 to 35 specified

If the height

specified

less than 05

mm

0 020 in

ST20050240

INSPECTION Wash all the disassembled parts except release bearing and disc assem bly in suitable cleaning solvent to remove

dirt and grease before

inspection

and

making

adjustment CL112

Flywheel

and pressure

plate

Check friction surface of and

Fig

flywheel

plate for scoring Slight roughness may

pressure

roughness

ed the

deeply scored or part should be replaced

MeOlUring disc runout

Check the

or

transmission

be

smoothly sliding

smoothed by using fme emery cloth If surface is

5

CL ll

groov

clutch disc be 04

replaced mm

fit

of disc hub drive

main

or

If

splines

gear

on

are worn

main drive gear should

that is backlash exceeds

0 016 in at the outer edge of

clutch disc

Clutch disc

loose torsional springs

for

worn or

oily

and broken

or

Clutch cover I

Check

Fig 3

CL 13

the end surface of dia

phragm spring for

wear

4 CL

the spring height wear or

invisible As these parts from outside shake cover assembly up are

damage

down

noise

assembly

AdjlUting

Inspect thrust rings for

and

llembly at

Inspect clutch disc facings loose rivets

CL152

for

or

slightly noises

to

lightly

listen

for chattering

hammer

on

rivets for

mean

a

Any of these requirement for replace

cracked noise

ment as a complete

assembly

CLUTCH Pilot

Release bearing and sleeve Check for abnormal

Check

wear on con

tact surface of withdrawal lever

bushing

ball

for

wear

replace

pin and bearing sleeve

pilot bushing roughness

or

in crankshaft If necessary

When bushing is faulty be sure to check transmission main drive gear at the

same

time

it

CLUTCH CONTROL CONTENTS CL B

Inspection

CL 5

DESCRIPTION PEDAL

CL 6

OPERATING CYLINDER

Removal and installation

CL 6


CL B

I nspection and

CL 6

Disassembly and assembly

CL B

Inspection

CL B

CLUTCH

adjustment

CLUTCH MASTER

CYLINDER

CL 7


CL 7

Disassembly and assembly

CL 7

forwards clutch fluid to the

DESCRIPTION The

hydraulic clutch control con sists of a pendent pedal a master cylinder an operating cylinder and a

the

piston of the

via

of the

operating cylinder piston

through

the

a

to

is

the withdrawal lever

push

rod thus

disengaging

is

The operating

cylinder

is

a

CL B

type that uses no return unit the withdrawal to In this spring rod push play adjustment is not neces

adjustable

sary since the CL 15 serves sate

the clutch

depressed master cylinder

pedal

operating

pipe line The movement

cylinder

transmitted

withdrawal lever When the clutch

BLEEDING CLUTCH SYSTEM

CL B

for

wear

as shown in Figure automatically compen

8

to

on

the clutch disc

non

2

I

l 1

Clu tch pedal

2

Return

spring

Clutch master cylinder 4 Clutch piping 3

5

Operating cylinder

6

Push rod

7

Withdrawal lever

8

Release

9

Clutch

10

5

bearing Cl305

cover

Clutch disc

Fig CL14 Clutch operating system CL 5

CLtJTCH Stroke 30

I i Jt

Sj 1

J i

Fig CL 15

Non adj

mm

in

18 1

o

table operating

cylinder 1

Lock nut A

CLUTCH PEDAL

2

Lock nut


Pedal beiBht a 53 mm 6 02 in 117 10 23 4 6 Pedal full stroke b

Removal See 1

Pry off

clevis pin

@

CL 16

Figure

pin and take

cotter

8

104

84 in

Multipurpose grease

out

disconnect push rod from

CL102

pedal assembly

Fig CL 17 Adju ting pedal height

Unhook return spring Loosen off fulcrum pin and remove pedal as 2

Note

sembly

Refer to Figure Clot8 for the

correct direction of return

CfJ ch 1

2 3

Return spring Pedal boss

S

Pedal

6

Bush

7

8

Nut Push rod

9

Fulcrum

W5

fD

2

Turn in until

screw

Then

A i

pin

clutch

removing

or

out

play

push

lock

pin

nut

1

Pedal assembly

2

Push rod

3

Return spring

Fig

pedal pedal

CL 1B

Hooking

return

pring

Note

Exercise

play

Installation the

order

of

multi purpose grease to the friction surfaces of the disas sembled parts as shown in

3

Apply

Figure

CL 17

Tightening torque Pedal installation bolt

Fulcrum pin 19 to

14 Lock nuts

4 2

kg

m

to 17 ft Ib

A

and

0 8 to 12

B

kg m

5 8 to 8 7 ft lb

m

5 8

adjusting 0 039

mm

is obtained B

to

the

m

5 8

eL116

not

care

in

adjusting

port or A blocked port

cylinder

After adjusting

play at

Clean all the following parts in cleaning solvent and check for wear damage or any other abnormal condi tion Replace the parts which are faulty Return spring 1 2

Bush

3

Pedal boss etc

CL 6

clevis

check the pedal

full stroke is in 117 to 123

Inspection and adjustment

the

block the

to

may result if too small pin exists reverse

rod

of I to 3

at clevis

tighten

master

install

kg

specified torque 0 8 to 12 kg to 8 7ft Ib

pad

removal

a

to 0 118 in

note toe board clearance at

12

to

to 8 7 ft lb

pedal

To

pedal height to 153 by adjusting pedal stop tighten lock nut A to the

6 02 in

specified torque 0 8

ll

assembly

Before

the

Adjust

per and

Fig CL 16 Exploded view of clutch Note

spring

3

ij

aevis pin Cotter pin

4

6

1 mm

mm

4 61

to 4 84 in

Note

Depress pedal over sure

erates

noise

that

and

release

clutch

its entire stroke to

the

clutch

en

linkage op smoothly without squeak interference and binding

CLUTCH cylinder to the vehicle and dismount master cylinder

CLUTCH CYLINDER MASTER

Note


Remove dust

cylinder body er

s

cover

on

2

Bleed air out of hydraulic system

Tightening torque

from master

Master cylinder to dash panel

the side of driv

0 8 to 1 2

seat

Clutch tube connector Flare nut

Installation

Removal I 2

To

Remove clcvis pin at push rod clutch tube from

removal

Disconnect

master 3

bolts

Disassembly

securing

and

5 to 1 8 1 reverse

Closely

the order

observe the

of

II

following

instructions

3

1

Adjust pedal height by changing

GG94310000

pedal stopper length

to

cylinder and drain clutch fluid

Remove

install

master

kg m

5 8 to 8 7 ft lb

Flare Nut

Using

kg

m

to 13 ft lb

Torque

tighten each the specified torque

Wrench

connector

assembly

1 2 3 4 5

6 7

8 9 10 11

Reservoir cap Reservoir Reservoir band

Cylinder body Supply valve stopper Return spring Spring seat Valve spring Supply valve rod Supply valve Primary cup

12 13

Piston

14 16

Secondary cup Stopper Stopper ring

17

DU5t

18

Lock nut

15

Push rod

cover

CL265

Fig CL 19 Exploded view of maater cylinder

Disassembly Remove dust

1

Assembly cover

and remove

stopper ring from body 2

Remove

push

rod and piston

as

sembly 3

Take off piston cups 4 Remove spiing seat from piston and take off supply valve if necessary See Figure CL 19 Note

Discard piston cup supply valve and spring seat after removal

To assemble

Note reverse

disassembly Closely lowing instructions

the order of

observe the fol

I

Dip piston cup in brake fluid before installing Make sure that it is correctly faced in position 2 Apply a coating of brake fluid to cylinder and piston when assembling 3

Press piston into spring seat when

assembling CL 7

The clutch master

cylinder

is

available in both NABCO make and TOKICO make

There is

no

com

changeability ponent parts

between NABCO and

repair

kits

inter

of

or

TOKlCO makes When

replacing

component

the

parts

repair

ascertain

brand of the clutch IIIBSter

body Be same

make

sure as

kit

to use

or

the

cylinder

parts of the

the former

ones

CLUTCH

Inspection or wash all parts of cylinder operating cylinder and piping clean brake fluid must

To clean

Note

and

Disassembly assembly

badly

too

damaged

beyond speci

fications

master

be used Never

minera10ils llUch

ton

cylinder and piston for wear or damage and if neces

Check

If the clearance between

piston

is

Renew

assembled when

more

than

dust

3

Remove

piston assembly and pis

It must

wear

spring The hydraulic clutch system must be bled whenever clutch line has been

Remove bleeder screw

also be

1

replaced

1

Push rod

n

6

Cl11B

Dust

3

Piston spring Piston

4

from

Bleeder

inder so that outlet hole is free from

Assemble in the

1

order of

reverse

Prior to assembly

dip piston

When

installing

cup

pay

particular

attention to its direction

Detach clutch hose from operat

ing cylinder

2

Remove

two

Install in the

reverse

order of

b The re

moval

Bleed air thoroughly from clutch

hydraulic system clutch

install return will

not

be

spring or disengaged

piston assembly

piston spring place clutch operating cylinder

changeability

of

When

replacing

component inder

Tightening torque

repair

no

the

kits

or com

the

bndy

same

repair

screw

0 7 to 09

m 5 1 to kg

5 ft Ib 6

Clutch hose connector 17 to 2 0 kg

m

12 to 14 ft b

4

Close

clutch

as

bleeder

pedal

clutch

with bleeder

slowly

quickly

screw

as

is on down stroke

Allow

5

pedal screw

Repeat steps 4 and

use

or

to

return

closed

5 until no air

several

times

check connections for external

Notes a

b Brake fluid containing out

of bleeder

no

screw

air

runs

a

solid

in

stream without air bubble c

Pay close attention to clutch fluid level in reservoir during bleeding

operation d Do not

ones e

Inspection

Brake fluid containing air is white and has visible air bubbles

the

parts of

the former

clutch

Operate

then

operating cyl

Be sure to

make

kit

ascertain

parts

loosen bleeder

to bleed air out of clutch sys

screw

inter

Operating cylinder securing bolt 5 to 3 2 5 kg m 18 to 25 ft lb Bleeder

pedal two pedal depressed fully

ponent parts between NABCO and TOKICO makes

brand of the clutch

properly

is

available in both NABCO make and There is

worker depress clutch three times With clutch

hydraulic leaks

in

TOKICO make

Observe the following instructions

clean

a co or

7

Be sure to install

with

Installation

a

bubble shows in the vinyl hose

Notes

housing

Have

6

bolts securing op

to clutch

a

2 Do not

in clean

Dip cylinder and piston

brake fluid before assembly

erating cylinder

Place the other end of it in

tern cup

in clean brake fluid

Removal

foreign rnaterial Install bleeder hose vinyl hose on bleeder screw any

3

disassembly Closely observe the fol lowing instructions


screw

container

Assembly

OPERATING CYLINDER

of operating cyl

Operating cylinder screw

bleeder

clean mud and dust

7

de

is found

Thoroughly

6

Fig CL 20 Exploded view of operating cyUnder

clutch hose and tube if or

cover

with recommended brake fluid 2

Piston cup

es

Remove reservoir cap and top up

I

5

2

weak

sign of damage

spongy

is an indication that air has

it

Bleeding clutch system is an sential part of regular clutch service

reservoir

should be replaced Return spring and valve spring must also be replaced when they are broken

any abnormal

action has a

entered the system dis

cap

Replace

air has entered it

or

pedal

When

feeling

mm

deformation due to

or

fatigue or damage is found 4 Damaged dust cover oil

fro ti

BLEEDING CLUTCH SYSTEM

cylinder 15 0

replace cylinder piston cup when

0 0059 in

2

with

disconnected

and

1

rod

push

replace

2

5

Remove

lic system

sary

or

1

cover

2

uneven

or

Disassembly

ruin the rubber parts of the hydrau

I

3

It will

and kerosene

gasoline

as

use

reuse

brake fluid drained

during bleeding operation Exercise care not to splash

brake

fluid

it will

on

exterior fInish

as

damage the paint disassembled

Visually inspect all parts replacing those found rl

Q

worn or

f Pour brake fluid into reservoir up to specifIed level

CLUTCH SERVICE DATA AND SPECIFICATIONS Clutch cover Clu tch

C225S

Diaphragm

type

cover

mm

in

33 to 35

Unevenness of diaphragm spring toe height

mm

in

less than 0 5

Full load

kg Qb

Diaphragm spring to flywheel

distance

1 23 to 1 38

400 882

mm

in

0 1

mm

in

1 0 0 040

mm

in

225

Free

mm

in

8 3 to 8 9

Compressed

mm

in

7 6 to 8 0

Out of flatness of pressure Allowable

refacing

plate

limit of pressure

plate

0 020

0 004

Clutch disc

Facing

size

Outer dia

x

inside dia

x

thickness

150

x

x

3 5

8 86

327 0

to

x

5 91

Thickness of disc assembly

Number of torsion

springs

Allowable minimum

depth

facing

run

0 299 to 0 315

6 of

rivet head from surface

Allowable

0 350

out

in

3 0

0 012

mm

in

5 0

0 020

mm

in

4 0 016 0

mm

in

153

mm

in

I to 3

mm

in

117 to 123

mm

in

15 87

mm

in

0 15

mm

in

19 05

Allowable free at the outer

play of spline edge of disc

mm

Clutch pedal Pedal height

Play

at clevis

pin

Full stroke

6 02 0 039 to 0 118 4 61 to 4 84

Clutch master cylinder Dia of master

cylinder

5 8

Allowable maximum clearance between

cylinder and piston Clutch operating

0 0059

cylinder

Dia of operating cylinder

Yo

Tightening torque Clutch

assembly

to

flywheel securing

bolt

kg m

ft lb

1 5 to 2 2

kg m

ft Ib

19 to 2 4

Pedal stopper lock nut

kg

m

ft b

0 8 to 1 2

Push rod lock nut

kg m

ft lb

0 8 to 12 5 8 to 8 7

kg m

ftIb

0 8 to 12 5 8 to 8 7

Clutch tube connector Flare nut

kg

m

ft lb

1 5 to 18 11 to 13

Clutch hose connector

kg m

ftlb

17 to 2 0 12 to 14

kg m

ft lb

kg m

ft Ib

Pedal installation bolt

Master

cylinder

to dash

Operating cylinder bolt Bleeder

screw

Fulcrum pin

panel securing bolt

to clutch

housing securing

CL 9

5 to 2

lito 16

14

to 17

5 8 to 8 7

5 18 to 25 3

0 7 to 0 9 5 1 to 6 5

x

0 138

CLUTCH


Condition

Clutch slips

Probable

Slipping

and

cause

Corrective action

testing

of the clutch may be noticeable when any of the following symptoms is encountered

during operation I

Vehicle will not

2

Insufficient vehicle

3

Lack of power during uphill driving

respond

to

engine speed during acceleration

speed

Some of the above conditions

also

are

experienced when engine problem

detennine whether engine or clutch is causing the problem If slipping clutch is left unheeded wear and or overheating will occur no

on

is

clutch

urring First

oc

until it is

facing

longer serviceable

TO TEST FOR SLIPPING CLlJfCH

proceed

as

follows

to 31 MPH with During upgrade travelling engine gear shift lever in 3rd speed position shift into highest gear and at the same time rev up engine If clutch is slipping vehicle will not readily respond to depression of accelerator pedal at

run

Clutch Oil

or

W r

Clutch drags

facing

grease

worn on

excessively

clutch

d clut h

about 40 to 50 km h 25

r

cov

Replace

facing

Replace

pressure

Dragging clutch is particularly

plat

o

tpa

e

noticeable when shifting gears as follows

lace

especially

into low gear

TO TEST FOR DRAGGING CLlJfCH proceed

I

Disengage clutch Shift into reverse gear and then into Neutral Gradually engine speed and again shift into reverse gear If clutch is dragging gear grating heard when shifting from Neutral into Reverse

Start engine increase is

2

Stop engine and shift gear

3

Gears

are

Conduct this test at each gear position

smoothly shifted

in step

2

but drag when

shifting

to

1st

speed position

at

idling If dragging is encountered at the end of

a

shifting

check condition of

synchro

mechanism in transmission If dragging is encountered at the beginning of shifting

b 4

5

Push change lever toward Reverse side If pedal

b

Ifpedal cannot be

Check clutch control If

no

to

step

4 below

to check for free travel

be depressed further check clutch condition depressed further proceed to step 5 below

a

can

depress pedal

proceed

pedal height pedal

abnonnal condition exists and if

free travel withdrawal lever

pedal

cannot

be

depressed

play

etc

further check clutch

condition

Clutch disc runout Wear

or

or

rust on hub

warped

splines

Diaphragm spring

toe

justment

worn

Worn or

or

toe

tip

improperly

Repair or replace

in clutch disc

height

out of ad

installed parts

CL10

Clean and lubricate with grease or

Adjust

or

replace

Repair or replace

replace

CLUTCH

Probable

Condition

Clutch chatters

cause

usually noticeable when vchicle

is

Clutch chattering

Corrective action

and testing

is

just

rolled off with clutch

partially

engaged Weak

broken

or

clutch

disc

Replace

torsion

spring Oil

or

grease on clutch

Replace

facing

Clutch facing out of proper contact

Replace

or

clutch disc runout

Replace

Loose rivets

Warped

pressure plate

clutch

or

cover

Repair

or

replace

toe

Adjust

or

replace

surface Unevenness

of

diaphragm

spring

height engine mounting

Loose

deteriorated

or

Retighten

or

replace

rubber

Noisy clutch

A noise is heard after clutch is

disengaged

I

Damaged release bearing A noise is heard when clutch is

Insufficient grease of bearing sleeve Clutch

on

the

and bearing

cover

Replace

disengaged

sliding surface

Apply grease

not installed

are

Adjust

correctly A noise is heard when vehicle is suddei11y staited offwith clutch

I

Damaged pilot bushing Clutch grabs

Replace

grabbing of clutch occurs vehicle will not start clutch is engaged before clutch pedal is fully depressed When

Oil

grease

or

on

Clutch facing Wear

or

rust on

smoothly

Replace

loose rivets

splines

off

Replace

clutch facing

worn or

partially engaged

in drive shaft and

Clean

or

replace

clutch disc

Repair

Warped flywheel or pressure plate Loose

mountings for engine

or

train units

CLll

power

or

Retighten

replace

from

a

standing

start

or

Cl Ul CFf SPECIAL SERVICE TOOLS Tool number

For

No

Description

tool name

Unit

mm

Base plate

or

page

on

Figure

in

620

ST20050010

Reference

use

No

Fig

CL 12

Fig

CL 13

Fig Fig

CL 2

Fig

6 CL

B210

00

710 610 S30

y

2

ST20050051 Set bolt SE002

q

3

ST20050 100 Distance

piece 7 8

@ mm

0 31 in

@1 @J SEOQ3

4

620

ST20050240

B210

Diaphragm adjusting

710 610

wrench

S30

SE032

5

KV30100200 Clutch

aligning

bar

This tool is used to conduct disc centerilg by inserting the tool into pilot bush in flywheel when installing clutch assembly to

620

flywheel

610

710

CL 3

S30

SEaOl

6

STl6610001

620 710

Pilot bushing

610

puller

S30

SE191

CL 12

CLUTCH

Tool number

Description

No

tool

7

Unit

name

GG94310000 Flare nut

torque wrench

mm

nut

A

accuracy

y

CL 13

SE227

Reference

use

page

on

Figure No

or

in

tighten and loosen brake and clutch tube flare assure torque in built torque limiting wrench is provided to


For

All models

Page CL 7

SECTION MT

MANUAL TRANSMISSION


TRANSMISSION TYPE F4W71 B

MT 2

5 SPEED TRANSMISSION TYPE FS5W71 B

MT 14


MT 21

TROUBLE DIAGNOSES AND toRRECTloNS

MT 23


MT 24

SPEEo 4

I NIS

J


LTD JAPAN

Manual Transmission

4 SPEED TRANSMISSION

TYPE

F4W71B


MT

2

GEARS

REMOVAL

MT

4

BAULK

Oil SEAL

DISASSEMBL Y

MT

4

MT

4

OF GEAR ASSEMBLY

MT

5

FRONT COVER ASSEMBLY

MT

B

REAR

MT

8

ADAPTER

MT

8

GEAR

REAR EXTENSION ADAPTER

RING

DISASSEMBLY

TRANSMISSION CASE D ISASSEMBL Y

AND SHAFTS

DISASSEMBLY

PLATE DISASSEMBLY

INSPECTION

ASSEMBL Y

TRANSMISSION CASE AND REAR EXTENSION

EXTENSION ASSEMBLY PLATE

ASSEMBLY

HOUSING

BEARING

MT

B

MT

8

8

MT

9

MT

9

MT

9

MT

9

MT

9

MT

9

MT

9

ASSEMBLY

TRANSMISSION ASSEMBLY

MT

MT13

INSTALLATION

MT14

DESCRIPTION The

transmission is of

forward

a

fully synchronized

4

speed

constant

mesh type that uses helical gears The reverse gear is ofa sliding mesh

type using

spur gears

In construction the main drive gear

pUshed

the inner teeth of the coupling

sleeve slide

over

the synchronizer hub

and mesh with the outer teeth which

provided on the mainshaft gear The synchronizer hub is fitted to

are

The transmission assembly consists of three main

which

to

parts

a

with clutch housing

case

an

installed and

gears

transmission

adapter plate

and

shafts

are

rear extension

The cast iron

adapter plate supports

is meshed with the counter drive gear

the mainshaft by splines so the main shaft gear turns together with the

the

which is

mainshaft

idler

The forward speed gears on the coun tershaft are in constant mesh with the

The baulk ring serves to synchro nile the coupling sleeve and mainshaft

bolted at the front to the transmission

mainshaft gears which ride on the mainshaft freely through the needle

gear

extension

bearing

keyed

When

to

the countershaft

shifting

is

accom

Placing

the control lever in

position brings the

reverse

case

countershaft

reverse

shaft and three fork rods

and

at

the

rear

to

the

and

rear

by means of through bolts all By removing these bolthroughts

reverse

idler gear

mainshaft

gears and shafts

are

stripped

into mesh with mainshaft reverse gear

e

TM 858

1

Front

2

Transmission

3

Adapter plate Bearing retainer Rear extension hOUsing

4 5

cover case

Fig MT 1 F4W71B lrammiasion MT 2

case

compon nt

Manual Transmission

o cCl

1

Main

2

Baulk ring

3

Synchronizer hub 3 r

4

Shifting insert spnng Shifting insert Coupling sleeve

5 6 7

TM857

Fig MT 2 F4W71B

drive gear d

4th

3rd main gear

8

Mainshaft

9

2nd main gear main gear

10

1st

11

ht gear spacer

12

Reverse main gear

13

Counter drive gear

14

Countershaft

15

Reverse

16

Reverse idler

17

Reverse idler gear

counter

transmlsBIO n

gear

shaft

gear component

@

4 @

4

Striking lever Lock pin Oring Striking guide

5

Oil sea1

6

Striking rod E ring Stopper guide pm Return spring plunger Return spring

1

fl

2

3

t

7 8

@

9 10

13

Reverse check spnng Return spring plug Check ball plug

14

Check spring

15

Check baD Interlock ball

11 12

16

o

n

f1f@

17 18

Retaining pin 1st

2nd

19

ht

20

3rd

2nd fork rod 4th fork rod

21

Reverse

22

3rd

23

Reverse shift fork

24

Con trollever

25

Control lever b shmg

26

Control lever p

27

Control lever bushmg

@

shift

ork

fork rod

4th shift fork

n

TM045A

Fig MT 3 F4W71 B 3 MT

transmuswn

shift controI components

Manual Transmission 9

REMOVAL dismounting transmission from

In

proceed

the vehicle

as

follows

Disconnect battery

I

cable

ground

Remove

bracket

holding

center

bearing on 3rd crossmember by loosening off attaching bolts See 6 MT

Figure

from terminal Place transmission control lever in

2

neutIal position 3

Remove E

pin

from and

guide

ring and control lever striking rod

transmission remove

control lever See E A277

4 MT

Figure

8 MT

Fig

Removing engine mounting rear

PD219

Fig MT 6 Removing center balring holding brucket

propeller shaft from companion flange of gear carrier by removing four bolts See Figure MT 7 10

Uetach

15

Remove starter motor

16

Remove bolt

support

securing transmis

sion to

engine After removing these bolts support

the engine and transmission with jacks ion rearward and then slide tra from engine and

away

from

remove

the vehicle

TM335

Fig MT 4 Remouing controllelJ r

a

Not Remove as

Jack up the vehicle and support weight on safety stands Use a

4 its

hydraulic

hoist

or

open

pit

if avail

and

safety

carefully propeller damage spline sleeve yoke

rear oil

oil from

Disconnect exhaust front tube

6

Disconnect

wires

from

rear

Figure

MT 5

8

I

transmission

cable See

O

case

See

cylinder Figure

cover

from trans

Remove release bearing and with

Fig MT 7 Remouing four bolt 6ecuring prop ller shtJft to companion ltJnge

m

Support engine by locating

11

a

jacft pan with a wooden used between oil pan and jack block under oil

12

Support

transmission

with

lamp switch

4

Remove

5

Move gear to Neutral

reverse

Remove speedometer pinion and pinion sleeve by taking off lock plate 6

7

Remove E ring and stopper guide rear end of ll extension re

pin from See

Figure

MT 9

a

transmissionjack

@

pipe btacket by unscrewing attaching bolts 2 California models only See Figure 13

Remove exhaust

8 MT

Speedometer cable Reverse lamp switch Outch operating cylinder

14

Remove

insulator TM774

Fig

thoroughly wipe

transmis

off dirt and

drawallever

J

3

disassembling

Remove dust

3

P0220

1

to

grease from it 2 Drain oil thoroughly

MT5

2

Prior

mission case

Remove clutch operating

from

DISASSEMBLY

sion

extension housing

dismounting trona adjacent

TRANSMISSION CASE DISASSEMBLY

reverse

speedometer

Disconnect

from

in

out

flowing

lamp switch See Figure MT 5 7

care

seal

is insured

5

Take

mission not to strike any parts and main drive shaft

so

b Plug up the opening in the rear of rear exteDSion housing to prevent

able Confirm that

not to

Note

shaft

MT 5 Bottom view of car

rear

securing

engine

bolts

I

mounting and

rear

mounting member securing bolts 3 8 MT See Figure 4 MT

TM337

Fig MT 9 Removing triking rod E ring and topper pin


Remove return spring

spring

reverse

from

er

rear

plug

return

check spring and extension

plung

See Figure Fork rod

MT 10

ht

2nd

qJiiiiiI

TM341

Fig MT 13 Removing trammission Interlock

case

ball 13

TM338

Fig MT 10 Removing return spring plull

Set

Setting Plate Adapter ST238 1000 I on adapter plate With countershaft side up place the above assembly in a vise See Figure up

MT 14 TM344

Remove

9

rear

bolts and turn the

extension

Fig MT 16 Layout

securing

o

ch ck boll

and interlock ball

striking rod toward

left Drive out rear extension backward

by lightly tapping around it with hammer See Figure MT 11

a

Gear assembly

soft

I

With gears doubly engaged

out TM342

Fig MT 14

Attaching l to

mbly special tool

or

suitable

each Fig MT 11

Removing

rear

extension

fork rod

Punch

Draw

out

counter drive gear

with main drive gear means of a gear puller

plete

Fork rod

TM339

Remove counter drive gear snap

3

ASSEMBLY

from

retaining pins with

ST23540000

Fork

Rod Pin

See

a

Figure

ring

DISASSEMBLY OF GEAR

out

See

puller

gear

MT 17 2

Drive

draw

countershaft front bearing using

Figure

When

out

be careful

assembly needle bearing front

MT 15

drawing

end

com

assembly by

main drive gear

not to

onto floor

of mainshaft

drop pilot from See

the

Figure

MT 18 Remove

10

bolts and

front

remove

front

cover

securing

cover

S

Detach countershaft front bearing shim Remove main drive bearing snap II ring with Expander See Figure MT 12 ST23540000 TM343

Fig MT 15 Drive 2

Remove three 3

out retaining pim

check ball

piugs

and drive out fork rods from adapter pia te by lightly tapping on the front

TM398

Fig MT 17 Removing countershaft front b aring

end

j Separate transmission case from adapter plate with a soft hammer See 12

Figure

MT 13

Be careful not to lose three 3 check balls and four 4 interlock balls See

Figure MT 16

Each gear and shaft can be detached from adapter plate with

Note

out

removing each MT 5

fork rod

TM345

Fig MT 18

Removing count

r

drive

gear and main drive gear

Manual Transmission Remove snap ring and then thrust washer from mainshaft front end 4

Draw

out

assembly

4th

3rd

and

synchronizer 3rd

remove

gear

as

sembly 5

Release

nut

caulking

and loosen it

on

mainshaft

sembly together with countershaft by lightly tapping the rear end with a soft hammer while holding the front of mainshaft gear assembly by hand Be careful not to drop off gear shaft See Figure MT 20

See Figure MT 19

2

Press out I st gear mainshaft bush

ing together with 2nd gear and 1 st 2nd speed synchronizer using Bearing Puller STJ0031000 See Figure MT 2l Note

When r

h ft

hold

drop

out bushing by hand so as not to

it

IJ

H

t I

TM346

Fig MT 19

Removing maimhaft

nut

TM347

Fig MT 20 Driving out gear

embly

Cl

30031000 S1 6

Remove

mainshaft

washer and mainshaft 7 shaft

nut

reverse

thrust Mainshaft assembly

gear

Remove snap ring from counter rear end and remove reverse

idler gear 8

Draw

1

not out

mainshaft

gear

as

Remove thrust washer steel ball

I st gear and needle

bearing

to lose steel ball

washer

Be careful

retaining thrust

TM049A

Fig MT 21 R moving lItgear mtUlIIhaft bu hing

12

1

Pilot bearing

2

3rd

3

assembly Baulk ring

4th synchronizer

5

3rd main gear Needle bearing

6

Mainshaft

7

Needle bearing 2nd main gear

4

8 9

1st

2nd synchroni

r

assembly to II 12 13 14 15

Coupling sleeve Shifting insert Shifting insert spring Synchronizer hub 1st main gear Needle bearing

16

1st gear

17

Thrust weher Maimhaft bearing

18 19

bushing

20 21

ReftllSe main gear Thrust washer Nut

22

Steel ball

23

Thrust washer

24

Snap ring

TM348

Fig MT 22 Explod d view of 6 MT

haft main

mbly

Manual Transmission

M in drlv 1

Count

r

g

r

h ft

mbl

Install Bearing Puller STJOO31000

Remove main drive gear snap ring

countershaft

on

and spacer 2 Remove main drive bearing with Bearing Puller ST30031000 and a suit

countershaft

rear

rear

bearing

press out

bearing through

a

rod

See Figure MT 25

able piess See Figure MT 23

Main drive bearing Main drive gear

1

2

TM349

Note

Fig MT 23 Removing main drive bearing

When

pressing

shaft by hand

so

out as

bearing not

to

hold

drop

shaft onto floor

III

cl

1 2

iiiiiE

Snap ring Spacer

l

drive bearing with snap ring

3

Main

4

Main drive gear TM351 TM350

Fig MT 24 Exploded view of main drive gear

q e

1

Fig MT 25 Removing countershaft bearing

f @ @

1

Countershaft front bearing

2

shim Countenhaft front bearing

3

Snap ring

4

Countenhaft drive gear

5

Woodruff key

6

Countenhaft

1 8

Countershaft rear bearing Reverse counter gear

9

Snap ring

j

i TM352

Fig

MT 26 Exploded view of

MT 7

haft auembly counte

Manual Transmission REAR EXTENSION

Note

DISASSEMBLY lock

Remove and

lever

remove

00 not diSlssemble

sion bush from

pin from striking rod

rear

exten

rear extension

striking

e

1

Control lever

2

Striking rod guide Striking rod Striking lever Return spring plug Stopper pin

3 4 5

6

TM353

Fig MT 27 Exploded view ofshifting mechani6m

ADAPTER

PLATE

Remove

DISASSEMBLY I

Remove

attaching

wrench and from

six 6

bearing with

screws

remove

retainer

an

impact

bearing

retainer

nicks

projection

a

3

extension bush is

If

rear

or

frne stone

cracked

replace

bush and

rear extension

it

2

Check shaft for bending and

wear

as an

worn or

assembly of

housing

3

Remove mainshaft bearing from

reverse

idler shaft

BEARING

side

I

2

a

worn or

INSPECTION

of round

Wash all parts in a suitable cleaning solvent and check for wear damage or

with

clean bearing and dry

compressed

When

race

air

and ball surfaces

are

rough or when balls are out or rough replacebearihg

a new one

See

Figure

If the above limits

are

exceeded

drive and driven gears Measure gear end play

replace 4

as

a

set

1st gear 0 32 to

MT 28

39 0

mm

0 0126 to 00154 in 2nd gear

other faulty conditions

0 12 to

19 0

mm

0 0047 to 00075 in

Notes a

10mm to0

0 0020 to 0 0039 in

Thoroughly

with

crack

if necessary

spline

Standard 005

Remove

rear extension

worn

replace 3 Measure backiasii in gears

adapter plate

2

the

all

sealant with

Be careful not to

damage

any

3rd gear 0 13 to

parts

with scraper b 00 not clean wash

or

37 0

mm

0 0051 to 0 0146 in

soak oil seals

in solvent I TM372

TRANSMISSION CASE AND REAR EXTENSION HOUSING I

Clean

with

and

check

for

cause

oil

leak

solvent

thoroughly might faulty con

cracks which or

other

ditions 2

Check mating surface of the case to engine or adapter plate for small nicks projection

or

sealant

Fig MT 28 3

Replace damaged

l pecting ball bearing

needle

bearing

if worn or

GEARS AND SHAFTS I

Check all gears for excessive wear chips or cracks replace as required 8 MT

TM374

Fig MT 29 Measuring end play


Check for

stripped

damaged

or

speedometer pinion gear If necessary replace

2

ft lb

I

cracked

or

otherwise dam

aged excessively 2

baulk ring in position

Place

on

gear

holding baulk ring against

far

as

it will go

as

to 15

measure

gap

between baulk ring and outer gear If gap is small discard baulk ring

Insert reverse idler shaft in

2 er

Make sure that the cut out

of

reverse

ASSEMBLY

sion

clean seal seat in rear exten

housing

adapter plate

Install bearing retainer in adapter

plate Align bearing retainer with reverse idler shaft at the cut out portion of

REAR EXTENSION

Wipe

portion

idler shaft is lined up with

inner face of

torque

adapt

plate

3

1

gear cone While

12

m

if found to be

Replace baulk ring

deformed

16 to 2 1 kg

to

screw

BAULK RI NG

to withdrawal lever

Apply sealant

ball pin screw Install withdrawal lever ball pin to front cover and tighten

press fit oil seal in

place

Coat oil seal and bushing with gear oil for initial lubrication

this shaft torque

kg

m

screws

14 to 18 ft lb

screw at two

to 1 9 to

5 2

and stake each

poin Is with

a

punch See

Figure MT 34

See Figure MT 30 25 to 1

60 rom 0 0492 to 0 0630 in

1

lr 5

Front Baulk ring

h TM355

Fig MT 32 Rear extemion oil seal TM400 TM375

Fig MT 30 Baulk ring

to

cone

gap

Fig MT 34 Staking 2 er

OIL SEAL Discard O ring once

removed

sealing lip

is

or

oil seal which is oil

Replace deformed

seal

if

cracked

or

Also discard oil seal if spring is out of

Apply

grease to O

grooves in striking rod Insert striking rod with

guide through 3

torque

screw

4

striking

rod

rear extension

Install striking lever

of striking rod

SCN W

ring and plung

on

in

Install countershaft

bearing adapter plate by lightly tapping

around it with

a

rear

soft hammer

front end

Install lock pin and

to 0 9 to 12

kg

m

7

to

9 ft Ib

position GEAR ASSEMBLY ADAPTER

ASSEMBLY To assemble

disassembly

Clean all parts in solvent and dry the order of

reverse

Observe

ihe

following

instructions

Place dowel pin mainshaft bear ing and oil gutter on adapter plate and tap with a soft hammer until they are 1

properly positioned Use

FRON1

COVER ASSEMBLY

expand

cover then press fit oil seal in place Coat oil seal with gear oil to

MT33

Wipe

clean

seal

seat

in

provide initial lubrication

a new

on

in

place

rear

front side and

on

side

with

compressed

air

Synchronizer 888embly Assemble synchronizer assembly

dowel pin

Bend oil gutter

front

I

PLATE ASSEMBLY

See

Figure

J

Position shifting insert springs and shifting inserts in three 3 slots in

synchronizer hub put coupling sleeve on synchronizer hub

Front

Upper

r

Front

J f

r

Front

J C

MT 31

Front

cov

oil

eol

MT 9

33 MT

15t

2nd

TM351

Fig Fig

4th

M356

TM354

Fig

3rd

7

Oil gutter

MT 35 Installing synchronizer hub

Manual Transmission Malnshaft assembly I

2nd gear

Assemble 2nd gear

ing

needle bear

baulk ring

I st

ing

washer a

I st gear bush

ring

steel

gear

on

2nd

1st

speed synchronizer assembly baulk

st gear

apply

I

and

thrust

grease to

it See

Figure MT 36

Place

woodruff

new

keys

in

press main drive bearing shaft of main drive gear

ST23800000

lightly until they

onto

Use

a

seated securely

are

soft hammer

to

avoid dam

the

Make

sure

that snap

aging keys

shaft clears bearing

2

2

Place adapter plate assembly and mainshaft assembly so that counter shaft sion

rear

bearing

rests

on

Transmis

Press Stand KV31100400 prop

erly 3

on

main

Place

main drive

that

it

See

adapter Figure MT 39

Press

Stand

KV311 00400 and place adapter plate

assembly

it See

on

Figure

MT 37

TM440

39 MT

Fig 4 For counterman and reverse idler shaft For main5haft and

l talling

Thickness 1 80

0 0709

2

1 87

0 0736

3

1 94

0 0764

4

2 01

0 0791

5

2 08

0 0819

6

2 15

0 0846

UJ

V

Holes for reverse Idler

Fig 3

bearing gear baulk ring and 3rd 4th synchronizer assembly on the

front of mainshaft

CD

Insiall thrust washer on mainshaft

I

e ure it with snap ring of proper thickness that will fit the groove in

mainshaft See Figure MT 40

TM438

mainshaft

TM364

assembly

to

adapter plate assembly Be sure to place bearing squarely against shaft and press it into place on shaft gradu ally See Figure

Available snap ring

shaft

MT 37 Tromminion PreS3 S tond

Install

in

countersha t

and

J

mm

Position 3rd gear needle

S

V31100400

main

ifnOai Sfdh

reverse

tdler haft

bearing spacer

bearing and secure

Available snap ring

l talling thrust washer

Transmission

on

4l MT

Figure

TM358

Set

groove

bearing with thicker snap ring will eliminate end play See

drive

No

2

drive

ring

Install countershaft into

plate by pressing

Fig MT 36

Adapter

Transmission

Using

1

grooves in countershaft and tap them

needle bear

ball

mainshaft Before installing

steel ball

Main drive gear assembly

Countershaft assembly

No

Thickness

mm

in

Fig

Installing snap ring

41 MT

I

14

0 055

2

5 1

0 059

3

0 063

face of main drive gear

16

3

to

MT 38

on

Position baulk ring mainshaft pilot

on cone sur

Apply gear oil bearing and install it

mainshaft

Assemble main drive gear assembly on the front end ofmainshafl 4

Press

counter

drive

gear

onto

countershaft with Counter Gear Drift ST23860000 by secure

snap KV31100400

38 MT

Installing

Note

haft mai em

bly

gears

and

ring

See

Figures

MT 42 and

43 MT

TM439

Fig

meshing

counter drive gear with thicker

TM441

Fig

40 MT

l talling snap ring

MT l0

Be

drive

sure

gear

to

and

simultaneously

drive

in

main

drive gear

counter

Manual Transmission in a vise

Support adapter plate with Plate Setting 6

ST238 10001

Adapter mainshaft facing

with

mainshaft

washer

plain

on

the

reverse

rear

gear of mainshaft

and install mainshaft nut

Tighten

TM442

42 MT

Fig

l talling

haft counte drive gear

mainshaft nut

8

Install counter

rear

of countershaft and

map ring Use snap gear end

14

ring

play

See

temporarily

reverse

gear

on

secure

17

to

kg

with

torque

Install

7

of converted

torque

Mainshaft nut should be tightened to

down

ST23860000

Explanation

the

ST22520000 of

wrench

needle

to 123 ft lb

of

aid

Wrench

doing

When

amount

should

the

so

be

to

torque

read

be

on

modified

following formula

to the

according

101

m

the

with L

give a minimum Figure MT 45 to

C kg

14

m

to

x

L

O lO L

Available counter drive gear map ring

17

x

L

No No

Thickness

I

14

mm

15

0 059

3

16

0 063

10 0

in

mm

in

or

0 055

2

Thickness

I

14

0 055

2

15

0 059

L ft lb

C

101

to

x

33 0

L 16

3

0 063

L 123

x

L

33 0

II Where

C Value read

kg

the torque wrench

on

ft lb

m

L Effective wrench

of

length m

torque

ft

ST22520000

c

Torque wrench

Imtalling

counter

gear TM366

43 MT

Fig

Installing nap ring

9 verse

10 Press countershaft front bearing

5 onto

countershaft

ST22360002

with

Drift

C

See Figure MT 44

Install

reverse

reverse

With

I

nap ring

idler gear

on re

Lm ft O IOm TM587

0 33 ft

idler shaft 1st and 2nd gears

tighten mainshaft

engaged

h

TM361

o

45 MT

Fig

doubly

Fig

47 MT

Setting wrench

nut to the

converted

Cn See Figure torque using Wrench ST22520000 See Figure MT 47 MT 48

Example When que ST22360002

Figure kg ST22520000

KV3 II00400 TM443

Fig

44 MT

Installing

a

TM768

haft counte front bearing

Fig

46 MT

Tightening mainshaft nut

MTll

m

0 40

m

31 1

wrench is used

ft the

long

tor

Cn in

MT 48 will be 112 to 13 6

81 to 98 ft lb

Manual Transmission Secure

S

2 15

I

110

c

14

100

c

9 S c o

check

ball

check

Align notch

shift

check

ball

sealant to check ball

I 6 1r f fdl

15

to

retaining pin

and check ball plug

tightening

line

2nd fork rod

a new

Install

spring

Upper limit

u c

1st

fork with

s

ball

Prior to

plug

apply

plug

in 1st

2nd fork rod

with check ball See Figure

MT

50

Converted torque

13 90

I

C

Lower

80

limit line

11

TM367

U

Fig MT 50

fork rod

V

10

70

9 0 2

2nd

l talling 1st

Slide 3rd

3

0 3

0 4

0 6

5 1

10 L

05

0 7

0 8 2 5

2 0

adapter plate m

and

with

secure

Prior to

Note

fork rod

balls into

CO 1Vert d torque

48 MT

a new

retaining pin

It

Effective length of torque wrench

Fig

4th fork rod through 4th shift fork

and 3rd

Figure 4

4th mbling 3rd 2 interlock two own in dap er plat a

install

MT 16

Install check ball and check ball

spring 11

Tighten mainshaft nut to 101 123 17 0 kg m to

to

torque

stake mainshaft

and

groove of main shaft with Figure MT49

a

14 0

Note

ft lb

nut

The main drive gear and

coun

ter driVe gear should be handled as a

to

matched set

When you

punch See

replace a main

counter drive gear

or

replace

as a

be

sure

to

set of main drive gear

sealant to check ball

Align notch

drive gear

in 3rd

with check ball by fork

rod

as

plug

place 4th fork rod

sliding

necessary

3rd See

4th

Figure

MT51

and counter drive gear

ShUt fork

Apply

and install it in

nd fork rod

mbly I

Place

1st

groove

and slide 1st

TM362

2nd shift fork in

in 1st

2nd

sleeve

coupling

2nd fork rod through and 1st 2nd shift fork

adapter plate Prior to installing

2nd fork rod

1st

TM368

install 3rd

Fig

49 MT

Staking

haft nut mai

3rd

4th shift fork in groove in 4th coupling sleeve

Note

Shift forks for 1st

3rd Measure gear end

12

play

and back

lash Make the

specified

that

they

are

held within

values

For details refer to the instructions under topic

Inspection

are

one

2nd and

and the

same

parts Make

sure

4th

4th Fig MT 51 Installing 3rd fork rod

sure

that the long end of shift

fork for lot

2nd is

placed long

on

counter gear side and the

for 3rd

4th is

on

side

the

the

end e

5

Place

verse

shift fork in

shift fork and

secure

MT12

reverse

idler gear Slide reverse fork rod

with

a new

reverse

through re adapter plate and

retaining pin

Manual Transmission Note

Prior to

assembling

rod

instaU two 2

into

adapter

Figure 6

reverse

fork

Front

interlock balls

piate

shown

as

I

in

to

2

check ball plug

reverse

xt nslon ass

ar

I

TM369

Fig MT 52 Installing

fork

reverse

rod

With

Torque each check ball plug 5 kg m 14 to 18 ft Ib 2

to

1 9 to

for ht

2nd fork rod

longer than those for

sion onto

ID

2J1 Transmission case

that speed change cross lever engages with fork rod brackets correctly

2

Countershaft

3

front bearing Countershaft

4

Shim

Install washers and through bolts

and torque to 1 6 15 ft lb

1 2

to

kg

m

12

TM371

to

MT 54 Selecting countershafl front bearing shim

Fig

Available shim

4th fork rod

see

sliding

Countershaft front

A

sur

in

rnm

bearing shim

mm

in

that shift rods

and

operate correctly engaged smoothly

gears

are

TRANSMISSION ASSEMBLY lon Tranmis

I

JJ

graduaUy slide rear exten adapter plate making sure

No

Apply

@

shift

rev

gear oil to all

faces and check to

A

D A

fork rods in their neutral

positions

3

8

shim of thickness

mbly

Clean mating surfaces of adapter

2

fork rod and 3rd

a

snap ring

plate and fear extension Apply sealant to mating surfaces of adapter plate and rear extension

plug

Select

Fig MT 53 Fitting main drive

R

BaD

counter

fork rod with

bearing

is

to

measured

check ball See Figure MT 52

Note

bearing

follows See Figure MT 54 from front Measure depth A

end of transmission case

and install it in place

7

mbly

shaft front bearing

spring Apply sealant notch in

s

as

1

Install check ball and check ball

Align

r

Select countershaft front

shim

MT I6

eov

I

2 92 to 3 01

0 1150 to 0 1185

2

3 02

0 1189

3

0 1224

5 0 020 0

3 12 to 3 21

0 1228 to 0 1264

0 4 0 016

4

3 22 to

0 1268

0 1303

0 3 0 012

5

3 32

3 41

0 1307 to 0 1343

0 2 0 008

6

42 3

to 3 5 I

0 1346 to 0 1382

0 1

7

3 52 to 3 61

0 1386 to 0 1421

8

3 62 to 3 71

0 1425

mbly

ea

3 11

0 6 0 024

to

to

3I

to

to

to

0 004

0 1461

1 Clean mating surfaces of adapter plate and transmission case Apply sealant to mating surfaces of adapter plate and transmission case 2

Slide

transmission

case

adapter plate by lightly tapping soft hammer until

case

onto with

a

bears against

adapter plate

Carefully

Clean

cover

install main drive

bearing

bearing

Make certain that mainshaft rotates

freely Fit main drive

bearing

snap ring

to groove in main drive bearing by using Expander See Figure MT 53

mating

surfaces of front

and transmission case

Apply retain

and countershaft front

3

2

grease to shim selected to install front

transmission

case

with gasket

in place Install

through bolts

with washers

under them and tighten to 1 6 to 2 1 kg m 12 to 15 ft lb torque

Apply

sealant

to

threads

through bolts before installation MT13

Install speedometer pinion

bly

it on front cover

cover to

3

of

on

rear

that

Sure

groove in

extension

lock plate is lined up with speedometer pinion sleeve

install

through bolts

to 0 5

kg

4

assem

After making

m

and torque

to

04

3 to 4 ft lb

Install back up lamp switch and

torque

to 2 0 to 3 0

kg m 14

to 22

ft lb Be

sure

installation

to

apply

sealant

before


Apply

purpose

light

a

grease

coat

of multi

withdrawal

to

Install the transmission in the

release bearing and bearing sleeve in stall them

on

6

Install

and

cover

on

clutch

1

Before

control lever

gears to make

lever

sure

mission

temporarily through all

that gears opera

2

Ie

smoothly

to

rear

plate

installing

spline

reo

Install drain

plug

mating

lightly

apply

parts of clutch disc

mission to

ith sealant in place

0 9 to 2 1 kg

bolts

Tighten engine Figure MT 55

and filler plug

1

and trans

and main drive gear 3

Note

32 to 43 ft Ib

case

Before

grease

dean

installing

surfaces of engine

shift control

m

following points

tion to the

After connecting them with holder dust

5 9 kg

uf removal paying atten

order

verse

clutch housing

spring instaU housing

4 to

INSTALLATION

lever

to

securing

specifications

m

7 to 9 rt lb

TM773

Fig MT 55 Tightening torque

trans

See 4

Remove filler plug and fIll trans

mission with recommended gear oil to

the level of the plug hole

mately

5 SPEED TRANSMISSION

TYPE

I 7 liters

3

Approxi

pt 3 pt

FS5W71B


MT14

BEARING

MT19

REMOVAL

MT17

GEARS AND SHAFTS

MT19

DISASSEMBL Y

MT17

BAULK RING

MT19

TRANSMISSION CASE DISASSEMBLY

MT17

OIL SEAL

MT19

DISASSEMBL Y OF GEAR

MT17

REAR

ASSEMBLY

EXTENSION DISASSEMBLY

ADAPTER

PLATE

DISASSEMBLY

INSPECTION

ASSEMBL Y FRONT COVER ASSEMBLY

MT19

MT19

REAR EXTENSION

MT19

MT19

GEAR

TRANSMISSION CASE AND REAR EXTENSION HOUSING

MT19

MT18

ASSEMBLY

ASSEMBLY

MT19

TRANSMISSION ASSEMBLY MT19

MT

INSTALLATION

20

MT20

DESCRIPTION The

transmission

is

speed

fully synchronized

The 5

uses

a

5 speed

4

with

mesh type that

overdrive

of

forward

OD constant

helical gears

speed transmission covered

in

this section is similar in all respects to the 4 speed transmission type F4W71B stated

previously except

the

overdrive position of it The overdrive gear

Placing the control lever rides

on

the

mainshaft

freely through the needle roller bearing and counter overdrive gear is fitted to the countershaft by splines The overdrive synchronizer system is on the mainshaft rear side

drive position brings the

coupling sleeve

reverse

OD main

gear shaft into mesh with overdrive clutch gear

hub

The is

splines shaft shaft

MT14

in over

reverse

reverse

fItted so

to

on

OD synchronizer the

mainshaft

the overdrive gear

turns

on

together with the

by

main main

Manual Transmission

j I @

b

00

7 @ f

f

1

Front

cover

2

Front

cover

oil seal

3

Front

cover

gasket

4

Transmission

5

7

Adapte plate Maimhaft bearing Bearing retainer

8

Rear

9

Breather

6

case

extension

10

Rear extension oil seal

11

Sleeve yoke dust

cover

@3 TM046A

Fig MT 56 FS5W71B transmission

MT15

case

components

Manual Transmission

j

W h

I

l 1

Main drive gear

2

Baulk ring Shifting insert Shifting insert spring

3 4 5 6

Synchronirr c

hub

Coupling slee

7

3rd main gear

g

9

Needle bearing Mainshaft

10

2nd main gear

11

Bushing

12

1st main gear O revcrse synchronizer hub

13 14

Rever

15

Circlip

16

Thrwt

t7

Brake band

18

Synchronizer ring

19

Overdrive main gear

20

Overdrive gear bushing

21

Washer

22 24

Mainshaft nut Overdrive mainshaft bearing Speedometer drive gear

25

COlplteBhaft

13

26 27

gear block

mt bearing shim fr Countershaft front bearing

28

Countershaft drive gear Coontcrshaft

29

Countershaft bearing

30

Reverse counter gear spacer

31 32

C counter Rever

gear

33

rdrive counter gear Countershaft zear bearing

34

C untershaft nut

3S

Reverse idler lIhaCt

36

Reverse idlcrthrust washer

37

Reverse idler gear nc idler gear bearing Reye Reverse idler thrust w8her

38 39

TM041A

Fig MT 51 FS5W11B MT 16

trumiasion gear componenta

Manual Transmission

I

2 3 4

5

Oil seal

6 8

Striking rod Expansion plug Stopper guide pin

9

Return

7

j

t

e

spring

11

Return spring plug Return spring plunger

12

Check ball plUS

13

Check spring Check ball

10

@

Striking lever Lock pin Q ring Striking guide

14

Retaining pin

CD

Interlock ball ist

18

1st

19

3rd

20

Reverse

21

3rd

o

O

2nd shift fork 2nd fork rod

17

4th fork rod OD fork rod 4th shift fork OD shift fork

Revene

Con trol1ever 24

Con trol1cver pin

25

Con trollever bushing TM048A

control component Fig MT 58 FS5W71B trammi ion shift

3 Same

for the F4W71B

REMOVAL as

DISASSEMBLY TRANSMISSION CASE DISASSEMBLY Same

as

Draw out counter drive gear com

plete with main drive gear assembly by means of a gear puller When drawing out main drive gear assembly be careful not to drop pilot needle bearing onto floor from the front end of mainshaft See Figure 60 MT

TM756

for the F4W71 B

Fig MT 60 Removing counter drive gear and main drive gear

DISASSEMBLY OF GEAR ASSEMBLY

4

Rem6vesnap ring and then

thrust

washer from mainshaft front end Fork

rod

Same

as

Draw out 3rd

assembly and

for the F4W71 B

4th

remove

synchronizer

3rd gear

assem

bly Geer I out

Remove snap ring and then draw out speedometer gear and bearing 5

sembi

from mainshaft

With gears doubly engaged draw haft front bearing using a counte

suitable gear puller See Figure MT 59 2 Remove counter drive gear snap

6 TM398

Fig

MT 59 Removing countershaft

front bearing

ring MT 17

rear side

gea doubly engaged re caulking on countershaft and

With

lease

mainshaft nuts then loosen them Remove countershaft nut

Manual Transmission II

Remove reverse idler gear

12

Remove snap ring of mainshaft Draw out bearing using

end bearing Mainshaft

Rear

Puller

Bearing

KV32101330 Remove other snap ring of mainshafl end bearing See Figure MT64

IT

TM757

Fig

Removing counterahaft

61 MT

nut TM761

Fig

tw Note

When

sembly

removing

mainshaft

as

TM160

Draw out counter overdrive gear

end by using

from a

countershaft

outgear

sembly

KV32101330

loosen mainshaft nut

and bearing

Driving

Malnahaft

Fig MT 64 Removing 7

65 MT

haft mai nd bearing

rear

Same

Figure MT 62

for the F4W7IB

Main drive Same

suitable gear puller See

as

as

ear

for the F4W71 B

Counterahaft aaaembly 13

Remove

washer

mainshaft

mainshaft

nut

reverse

thrust

gear

Same

as

OD

for the F4W7l B

synchronizer and overdrive gear

REAR EXTENSION

14

DISASSEMBLY

Draw out mainshaft gear assem together with countershaft by

bly lightly tapping the rear end with a soft hainmer Me holding the front of mainshaft gear assembly by hand Be careful not to drop off gear shaft See Figure 65 MT

Remove

lock

lever and remove Note sion

pin from striking rod

siriking

Do not disassemble

bushing

from

rear

rear

exten

extension

TM758

Fig MT 62 Removing overdriv

count

r

gear and bearing

8

Remove counter reverse idler gear and spacer 9 Remove countershaft by lightly tapping the rear end with a soft

k

J l

hammer Be

careful

not

to

drop

J

off gear

shaft 10

Remove

reverse

idler gear snap

ring

@

r

1

Striking

2 3 4

Control lever

5

Striking

6

Reverse select plunger Reverse select plug

7 TM759

Fig

63 MT

Removing

reverse

gear

idler

lever

Striking rod Stopper pin rod

guide

TM767

nap ring

Fig MT1B

MT 66

Exploded

view of shifting mechanilm

Manual Transmission If the above limits

ADAPTER PLATE DISASSEMBLY

Same

exceeded

replace drive and driven gears 4 Measure gear end play

for the F4W71 B

as

are

as

set

a

4

39 0

er

0 0047 to 0 0075 in

Make mm

plate Align bearing

INSPECTION

faulty

Same wear

as

for the F4W7IB

screws

14 to 18 ft lb

m

at two

screw

Figure

to 1 9 to 2 5

and stake each

points with

a

punch See

MT 69

OIL SEAL

conditions

Same Notes a

adapter

retainer with reverse

this shaft torque

kg

Wash all parts in a suitable

other

plate

idler shaft at the cut out portion of BAULK RING

solvent and check for

that the cut out portion idler shaft is lined up with

Install bearing retainer in

6

0 0126 to 0 0154 in

adapt

sure

reverse

inner face of adapter

0 0146 in

screws

cleaning damage or

soft

a

plate

of

OD gear on mainshaft 32 to 0 39 mm 0 Fig MT 67 Removing

by

bearing

Insert reverse idler shaft in

5

3rd gear 37 0

7 to

m

hammer

0 12 to 0 19 mm

to

kg

it with

lightly tapping around

0 0126 to 0 0154 in

0 0051

filainshaft

Install

mm

2nd gear

0 13 to

to 0 9 to 1 2

screw

torque 9 ft lb

1st gear

32 to 0

Install striking lever on front end of striking rod Install lock pin and 3

as

for the F4W71 B

ASSEMBLY

Be careful not to

damage

with scraper b Do not clean wash

any

parts To

or

soak oil seals

TRANSMISSION CASE AND REAR EXTENSION HOUSING as

reverse

the order of in

structions

in solvent

Same

assemble

disassembly Observe the following

FRONT COVER ASSEMBLY

Same

as

for the F4W7l B TM764

for the F4W71 B

Fig MT 69 Stahing

REAR EXTENSION

screw

ASSEMBLY BEARING

Wipe clean seal seat in rear exten housing press fit oil seal in place Coat oil seal and bushing with gear oil for initial lubrication See Figure

Same as for the F4W7l B

I

7

sion

in

68 MT

GEARS AND SHA

around it with

Check all gears for excessive

chips or cracks replace 2

rear

bearing

soft hammer

a

GEAR ASSEMBLY

S r

I

Install countershaft

adapter plate by lightly tapping

as

Clean all

wear

with I

required

parts in solvent and dry

compressed

air

Front

Check shaft for bending crack and worn spline if necessary

Synchronlz

embly

r

wear

Same

replace 3

as

for the F4W71 B

Measure backlash in gears

Ov rdrlve Main drive and

Fig MT 68 R

ar

extemion oil

I

1st 2nd 3rd reverse

2

Apply

O ring

and

multi purpose

plunger

grease

grooves in

to

striking

mm

0 0020 to 0 0040 in

Assemble

2

Position Insert

striking rod with striking

guide through

rear extension

MT19

rod

reverse

OD synchro

overdrive

gear

assem

bly

rod

gears

r

assembly

mm

5th and

0 05 to 0 20

Assemble

nizer

0 0020 to 00039 in

ynchronlz

sea

counter drive gear

0 05 to 0 10

r

mbly

TM355

brake on

synchronizer

ring

band

thrust block and anchor block

overdrive clutch gear install circlip


Synchro ring

Assemble OD

nizer

reverse

OD

assembly needle bearing

gear

synchro bushing

OD gear assembly sreel ball and thrust washer on main

8andbrake

shaft Circlip

side Before installing steel

rear

ball

apply

3

Install

grease to it new

mainshaft

nut

and

tighten it temporarily 4

Install

counter

counter

5 th gear

countershaft Anchor

block

TM449

Fig MT 70 Imtalling overdrive gear assembly

Same

as

Install

for the F4W7IB

snap

bearing

ring

reverse

spacer

as

and snap ring

Main drive gear assembly Procedures F4W7IB

are

trans

the same as for the i n

except

Tighten mainshafl and

as

those for the F4W7IB

Shift forks and fork rods assembly as

for the F4W71 B

I

L

u

TRANSMISSION ASSEMBLY Same

as

for the F4W71 B

follows I

Insert countershaft and mainshaft

TM4S1

into

adapter plate and place adapter plate in a vise with setting plate

counter

dures for mainshaft nut are the same

Same

h

for the F4W71 B

new

tem

needle

idler gear spacer

Countershaft assembly Same

nut

gear

shaft nuts and stake nuts at groove in shafts with a punch Tightening proce

as

roller

Tighten

and

porarily 5

Malnshaft assembly

nut

reverse

bearing

Fig MT 71

R

MT 20

lJerse

idler gear

INSTALLATION Same

as

for the F4W71 B

Manual Transmission

SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Transmission type

F4W71B

FS5W71B

Synchromesh type

Warner

1st to 4th Warner 5th Servo

1

3

1

3

5

II

T

Shift type

i 2

i 4

1

2

R

4

R

Gear ratio 592 3

1st

2nd

2 246

3rd

1 415

4th

1000

321 3 2 077 308 1 1000

0 864

5th Reverse

Oil capacity

382 3

375 4

Final gear ratio

Speedometer

3 657

gear ratio US pt Imp pt

375 4

20 6 I 7 3

MT 21

20 6 3

2 0 4X

f 3

Manual iTransmission

TIGHTENING TORQUE Installa tion

Unit

Engine

to

transmission installation bolt

Transmission

to

engine

plate

rear

bolt

transmission

7 to 9

2 5 to 3 0

Crossmember mounting bolt

Propeller

32 to 43

0 9 to 1 2

installation bolt

18

to

22

0 8 to 1 6 to 8 3 2 to 43

shaft to diff installation bolt

ft lb

m

4 to 5 9

Clutch operating cylinder installation bolt Rear mounting insulator to

kg

23 to 31

4 to 33 2

17

to 24

12

to IS

Gear assembly Rear extension installation bolt

16 to 2 1

Front

1 6 to 2 1

12to IS

19 to 2 S

14 to 18

cover

Bearing

installation bolt

retainer to adapter

plate

screw

Main haft nut

14 0 to 17 0

Check ball

1 9 to 2 S

plug

lever lock

Stri

pin

Reverse select return

Speedometer Reverse

sleeve locking

plate

nut

lamp switch

year

oil

Ge

oil drain

r

plug

Ier

101 to 123

14

to 18

0 9 to 1 2

7 to 9

09

1 2

7 to 9

0 4 to O S

3 to 4

2 0 to 3 0

14

to 22

plg

2 S to 3 5

18

t02S

plug

2 S toTS

l8

to 2S

or

SPECIFICATIONS Gear backlash

Unit

mm

in

Maindrive gear to counter drive gear

0 05

to

0 10

1st gear

0 05

to

0 20 00020 to 0 0079

2nd gear

O OS to 0 20 0 0020 to 0 0079

3rd gear

0 05 to 0 20 0 0020 to 0 0079

OD gear

0 05 to 0 20 0 0020 to 0 0079

Gear end

0 0020

to

0 0039

play

1st gear

32 0

2nd gear

to

39 0

0 12 to 0 19

3rd gear

13 0

to

37 0

OD gear

32 0

to

39 0

Counter gear

01 to 0 21 0

Reverse idler gear

0 0126 to 0 0154 0 0047 to 0 0075 0 0051 to 0 0146 0 0126 to 0 0154 0 0004 to 0 0083

0 05 to 0 20 0 0020 to 0 0079

Clearance between baulk ring and gear All gears Counter

bearing adjusting

125 to 1 60 0 0492 to 0 0630 shim

0 6 0024 0 5 0 020 0 4 0 016 3 0 012 0 0 2 0 008 01

MT 22

0 004

Manual Transmission I

TROUBLE DIAGNOSES AND CORREGTIONS Probable

Condition

Difficult

to

intel11lesh

gears

Causes Jor difficu t gear shifting are classi fied to troubles concerning control system

Worn gear

When gear shift lever is and it is difficult to shift gears clutch heavy also be unsmooth First disengagement may

loose sliding part

and

transniissioo

make

that

sure

Corrective action

cause

shaft and

Replace

bearing

or

Insufficient operating stroke due to

Faulty

or

pair

worn or

or

replace

Replace

damaged synchronizer

clutch operates correctly

and inspect

o transmissi

Gear slips out of mesh In most

interlock b all worn

is

or

this trouble

cases

check ball

weakened In this

faulty

or

occurs

and

or

when

spring

is

when control system

the trouble cannot be

case

corrected by replacing gears and therefore trouble shooting must be carried out care

fully out

It should also be noted that gear

of mesh due to vibration

weakened fron t and

rear

engine

slips generated by

Replace

Worn interlock ball Worn check ball and

or

weakened

or

broken

Replace

spring Wom fork rod ball groove

Replace

Wom

or

damaged bearing

Replace

Worn

or

damaged

Replace

gear

mounts

Noise When

noise

ceases when

noise

occurs

indicati90

occurs

with engine idling and

clutch is disengaged

or

while shifting gears it is an th e noise is from transmis

that

fa

ule during engine

idling air fuel

Check

mixture and

idling

above procedure

Add

lubricant

Oil leaking due to faulty oil seal

ignition

or

Clean

sealant

Of

breather a

Replace

bearing Cyclic knocking sound at a 19W speed

Replace

bearing High humming

occurs

at

high speed

Damaged also occurs

readjust engine

oil

etc

clogged

timing After

improper

or

replace

with designated oil

Worn

Transmission may

or

when

sion

t

Insufficient

Worn

spline

Replace

Worn

bushing

Replace

j

MT 23

replace

Manual Transmission

SPECIAL SERVICE TOOLS Description

No

Unit

tool

Reference

For

Tool number

mm

in

Figure

on

name

ST23540000

Fig

All

For removal of fork rod retaining pin

or

page

use

No

MT 15

models Fork rod

pin

punch 150

L

5 91

i 10 0 39

2

ST22360002

dia

M llBT

For assembly of counter drive bearing

Fig

44 MT

FS5W Drift C

63A

oOler

dia

inner dia

3

ST23800000

32

126

23 0 91

SE034

All

For assembly ofmain bearing

Page

MT 1O

models Transmission

adapter

480 18 90

outer

dia

inner dia

4

ST238 10001

For

setting adapter plate in

a

44 1 73 31 122

SE037

71BT M

vise

Setting plate

adapter

74

2

91

MT 24

SE132

Fig Fig Fig

MT 14 MT 15 45 MT

Manual

Transmission

Reference

For

Tool number

Description

No

Unit tool

5

in

mm

page

use

Figure

on

name

ST22520000

71BT M

For removal and assembly of mainshaft nut

63A

Wrench

TIM

or

No

Fig MT46 Fig MT47

38mm 50 1

in

SE313

6

ST23860000

7IBT M

For assembly of counter drive gear

Fig MT42

Counter gear drift

7

KV31100400 Transmission

dia

38

inner

dia

30 331

For assembly of rnainshaft countershaft counte counter drive

50

outer

SE039

M 7IBT

drive gear and

bearing 48

press stand

0

189

75

Q

2 95

0

Fig MT 37 Fig MT 39 Fig MT44

J

I 0

8

STJ0031000

For

TM438

All

replacing bearing

models

Bearing puller

80 3 15 50 1 97

SE041

MT 25

Fig MT 21 Fig MT 23 Fig MT 25

Manual Transmission

For

Tool number

Description

No tool

9

Unit

name

KV32101330

Bearing puller

For removal of mainshaft end b

lg ari

Reference

use mm

counter overdrive gear and

in

page

Figure

on

63A

fM l

FS5W

bearing

7IBT M

11 300

81

SE308

MT 26

Fig

or

No

64 MT

SECTION AT

j

L

AUTOMATIC TRANSMlsSIO N

DATSUN PICK UP

I

MODEL 620 SERIES

I

DESCRIPTION

At

HYDRAULIC CONTROL SYSTEM

AT 4


AT 33

MAJOR REPAIR OPERATION

AT 36

TROUBLLDIAGNOSES AND ADJUSTMENT SERVICE

DATA

AND

SPECIFICATIONS SPECIAL SERVICE TOOLS

I NISSAN I

I


LTD JAPAN

2

AHD AT 59 AT 62


DESCRIPTION

The model 3N7l B automatic trans mission is a

fully

automatic unit con

element hydrau sisting primarily of 3 lic torque converter and two planetary

Two

gear sets

brake

dimulstipcle

clutches

dimulstipcle

one way sprag clutch provide the friction elements required to obtain a

the desir d function of lhe two plane

planetary

of the gear

automatic in relation

sets

gear

three forward ratios and

on

range

also be

manifold

constantly fed

are

one

ratios is

to

give

reverse

vehicle

fully speed

to

vacuum

signals

the transmission

provide the proper gear ralio for maximum efficiency and performance to

at all throttle

openings

R N D 2 1

9sition LP

I

used

2

for engine

2

range can

vehicle speed mission from

be selected

at any

and prevents the trans shifting out of second

gear I

I

be selected

can

range

at

any vehicle speed and the transmission will shift to second gear and remain in second until 10

vehicle

40

50 kmfh

to

25

I

gear

prevents the

position

range

transmission from

out of low

shifting

This is particularly beneficial for

maintaining maximum engin braking when continuous low gear operation is

Identification of number Arrangements See below

The torque

converter

is of

assembly can

nOlbe

from

rolling

Model code

disassembled for service JAPAN AUTOMATIC

0J

in

either direction This

position should

be

selected

whenever the driver leaves Ihe vehicle Thc engine may be slarted in Park

FLUID RECOMMENDATION Use

position

automatic

having R

Reverse

vehicle to be

range

operated

enables in

the

transmission

DEXRON

fluid

identifications

only in the 3N71 B automatic

I

MODEL

X2402

I

I

NO

4912345

I

Unit number

sion a

reverse

Neutral position enables the be started and

engine

driving

the vehicle

normal

LTD

Number designation

to

0

J

TRANSMISSION CO

transmis

direction

N

Identification number

to 30 MPH

welded construction and

Park position positively locks

the

I

hicle speed is reduced

v

approximately

the output shaft to the transmission case by means of a locking pawl to prevent

Fig AT

desirable

The model 3N71 B has six selector 1

can

performance surfaces

slippery

braking

and engine torque input V chide speed and engine

range provides

AT344

tary gear sets The two

Changing

2

for driving

a

band brake and

a

2

Drive range

is

run

used

without

for

all

driving conditions

Drive range has three gear ratios from the starting ratio to direct drive

IDENTIFICATioN

4 9

NUMBER

I

234 5

L Stamped position The hand

plate

is attached to the

side of transmission

shown io

Figure

AT I

AT 2

right

case

as

Serial production number for the month Month of production X Oct Y Nov Z last figure denoting the year A D

Dec


J o

II IIlI

r

I r

AT288

I

Transmission

2

Oil

ca

e

II

Governor shaft

12

Output

13

Rear extension Oil

3

pump Front clutch

4

Band brake

14

5

Rear clutch

IS

6

Front

16

7

Rear

17

Input Jlihafl Torque converter

8

One way clutch

t8

Converter

9

Low

19

10

planetary gear planetary gear Rever5e brake

pan Control valve

housing Drive plate

Tightening torque bolts and nuts kg

ft lb

T

@ @

T

@

T

5 5 33 1040 0 6100 8 4 106 0 5 to 0 7 4 10 5

T

2

@

CD

4105

T

T

T T

AT3

of

@ @

Oil distributor

Fig AT 2

T m

T

29 10

36

10110116 141016 4 5 to

5 14 10 18 0102 3 10 18 9 10 13 1

0 55100 75 4 105 0 25 10 0 35 2 to 3

Cross sectional view of 3N71B automatic transmission


HYDRAULIC CONTROL SYSTEM CONTENTS FUNCTIONS OF HYDRAULIC CONTROL

P

RANGE

PAR K

AT14

AT

4

R

RANGE

REVERSE

AT16

AT

4

N

RANGE

NEUTRAL

D1 D2 D3

UNIT AND VALVES OIL PUMP MANUAL

LINKAGE

AT

4

VACUUM

DIAPHRAGM

AT

5

DOWNSHIFT SOLENOID

AT

5

GOVERNOR VALVE

AT

5

D

CONTROL VALVE ASSEMBLY

AT

6

2

HYDRAULIC SYSTEM AND AT13

MECHANICAL OPERATION

FUNCTIONS OF HYDRAULIC CONTROL UNIT AND VALVES

Oil pump

Manual

strainer

I

I

I

diaphragm

RANGE

12

RANGE 2ND GEAR

source

oil

for

is

of

an

and

serves

I

of

the

port

Transmission Lower

port

Control

port

Pump

The hand lever motion

gear

space

remote

transmitted

control to

the hand s

compart

transmitted from

linkage

is further

the inner manual lever

in the transmission case from the range selector lever in the right center

par

tion of the transmission case

the

manual shaft

lever is A

I

Housin

4

Inner gear

2

Cover

5

Crescent

3

Ouler gear

suction

Pump

mechanically

ment

AT071

case

r

lever is localed in the driver

route

Oil pan Oil strainer bottom of the control valve Control valve lower

brake

MANUAL LINKAGE

valve line

pressure circuit

with the engine operation The oil flows through the following

Pump housing

appropriate

body

ly coupled

suction port

reverse

Lubrication

internal

Transmission

oil

Band brake

to drive the pump

suction port

regulate

to

1

converter

Low and

inner gear with the drive sleeve direct

body

valves

transmission components

lhe

pump

The

pressure and direct it

I

involute gear type The drive sleeve is a part of the torque converter pump

impeller

transmission

Rear clutch

control system The oil

AT 30 AT 32

solenoid These parts work in conjunc tion with valves in the valve body assembly located in the base of the

I

delivery delivery port e

Torque

I

case

control

downshift

I

Control valve

housing delivery

the

LOW GEAR

vacuum

I

OIL PUMP

pump is i medium

and

AT 28

t

pump for packing p oil oil pan through the oil A shift control is provided by

diaphragm

AT 26

Front clutch

Governor valve

oil

KICK DOWN

centrifugally operated hydraulic

control

I

Downshift solenoid

The

RANGE

linkage

Vacuum

AT 22 AT 24

the

two

con

2ND GEAR

RANGE TOP GEAR

tains an oil

from

AT 20

RANGE 2ND GEAR

governors on the output shaft

The hydraulic control system

RANGE

AT18

LOW GEAR

RANGE

Fig AT 3 Oil pump 4 AT

thereby

through

The inner manual

turned

pin installed

on

the bottom of

the inner manual lever slides rhe

manu

al valve spool of the conlrol valve thus

positioning the spool opposite rhe appropriate select posilion The parking rod pin is held in rhe groove on the top of Ihe inner manual

Automatic The

plate

rod

parking

pin operates the range and operates the mechanical lock system rod

p

at

The above described manual shaft is further

equipped with

switch

A

range p

the

inside

rotor

switch rotates

in

inhibitor

an

inhibitor each

to

response

When tne range is selected N

or

starter

engine

the

circuit

magnet be

can

started

is selected at

back up

R

lamp lamp lights

at

closes the

rotor

that

so

flow

When the range

circuit and the back up

velocity of

intake

m

mifold

increases

since

slow

is

the

inside the

mixture

Contrarily

when the engine speed increases and the flow velocity of the mixture in or

creases

the

when

carburetor

I c

C

r

11

Kickdown h

Dowri

switch

shift solenoid

is

closed

the manifold negative pressure increases Le tends towards vacuum and the

the

the rolor closes the

reaction

vacuum

Transmission

vacuum

Thus

at

loading

control valve is trans

trye

from

and the

Fig

most

the

vacuum

diaphragm

suitable timing for speed

change and lin e pressure is obtaine so that the most proper torque capacity is

AT 6

Downshifl80lenoid

signal to generaIe hydraulic rfe tly suited to the engine

a

pressure P mitted

AT089

reaction is reduced

obtained

against the transmitting

GOVERNER

the back of the oil distributoron the

ft sha tn y op as thar iJf tile speed output shaft thai is they operate at a speed in proportion 10 the vehicle speed The line press retis applied to

To

manifold

lkc inl

outp

transmission erate

torque

VALVE

The primary and secondary gover nor valves are installed separately on

the

al

those

t

same

valves

the input from the s through the transmission flange and oil distributor

control valve case

CD

The governor the

to ATOB7 1

2

Manual pia te Inhibitor switch

AT088

Manual shaft

Fig AT

4

Manual

pressure

in

linkage

vehicle

is led to the shift valve ofthe

control

valve

opposite

the

through

route of the output In

Fig AT 5 Vacuum diaphragm

proportion

shaft speed

ouiput

speed

rod

Parking

rear

this

manner

and line pressure

speed change

are

controlled

VACUUM DIAPHRAGM The on

vacuum

the

left

transmission

diaphragm

portio n of the

center

The

case

DOWNSHIFT SOLENOID

is installed

internal

struction of the vacuum

con

diaphragm

is

follows

as

and

A rubber

diaphragm The

tion in the center

manifold

through

negative a

vacuum

forms

engine

a

parti

intake

pressure l led tube and spring

applied to the front surfaceof the rubber diaphragm while atmos pheric pressure is applied to the back force is

surface The difference between pres sure to the front and ba K I

applied

surfaces

a

causes

reactIOn

vacuum

which activates the throttle valve of

inside valve

the control

the

transrhis

sion case

Wheri

accelerator

the th

pedal

engirie

suificientl

plre sure

is

fully

de

buretor is fU IIy

increased

towards

downshift

e

solenoid

is

dePresses

down switch

the

the

to

sp eed is not

the manifold

lowers

Le

atmospheric pressure

tends and the

of

a

19ca

accelerator pedal

stopper

ted in the

a

kickdown

middle of the

accelerator link is depressed by a push rod he kickdown switch doses cur

rent

flows

to

the solenoid

noid push rod is

depressed

the sole the down

shift valve of the control valvc insidc the transmi ssion case is the

speed

3rd cle

to

speed

Note

depressed nd changed forcedly fmm 2nd within a cerlaill vehi is

limit

Since

theki kdown

closes when the accelerator

pressed and opened but negative

T

magnetic type installed on the left re r portion of the transmission case When a driver requires accelerating power

arf rd The wries

a

pedal

is

ped

adjusted

omplete stro

arrangement

ccording AT S

m

eI

so

as

I

valve

swit h

secondary

T e secon ary valve is a contro valve Y hich receives line pressure an cqQ rols the governor pressu e When D

at

is

the manual valve is selected 2

applied

or

t

l

range line pressure

the ri

this valve from

g

sh aped

circuit

I

of

area

l and this I

v

is depressed

Jy

tI

lOW jr

Movemcnt of this valvl III

positillll 15

rronl

sr

simultaneously IS

press

port and lowered

to

re in

Iii

cenlrifugal v

fer cr

a

in

Olto

making

a

center dniin it

l5j is

stopped 1

d the

tllc

When thc vehicle is

the

c

doses the dr uit from

while

cirJ

force of this valve is zero

lve is balanced

At this

poini

a

govcr lOr pressurc yhich bali1 nced with th spr ng force occurs on IS Wh

e

of the

of

governor

switch

depr ssed from 7 i t I S I 6 of tiie whole stroke the a ccel rator 1

should be correctly

Operation

n

thc vehicle is st rted

nd the

centrifugal fqr incre ses this valve movcs slightly 10 Ihc oUlSide and as

Automatic Transmission the space from I to IS increases to the drain port space from 15 As

decreases

simultaneously

of

governor pressure

15

a

To

onlml valve

resull

j 1I5

S1I pre

force

1

to

J

J Q

Ai09

1

Fig AT S Output shaft with oil

CID

The governor

thus changes in response

I f

increases

and the governor pressure is balanced with the sum of centrifugal force and

spring

D@

l Governor

pressure the vehicle

distributor and

l

overnor

force

speed change centrifugal

r

m

@

Line

Operation

of prlmar

The

nor

OFF ON

l

Primary

2

Secondary governor Governor valve body

governor

4

Oil di lributor

5

Output

governor

minimum

the

speed

exceeds

speed

aBUlllI8

certain

level

I

Oil distributor

2

Governor nlve

3

AT092

Primary governor valve

4

body

Secondary governol valve

Fig

and when the vehicle a

V

iUQlli JlAU

governor pressure regulated by the secondary gover valve when the vehicle reaches the

closes

0

lft sh

Fig AT 7 Cr05s sectionallliew of

an

@

AT090

valve

which IS

is

valve

t

I

3

governor valve

pressure

AT 9

Exploded

view of governor

the

governor opens and forwards the gov ernor pressure 15 to the control

ASSEMBLY

CONTROL VALVE

valve

Flow cbar of control valve system

When

the vehicle is

stopped

the

pressure is zero However when the vehicle is running slowly this valve is depressed to Ihe center governor

and the groove to 15 the governor pressure

is closed since to the

applied

ring shaped area is higher than the centrifugal force of this valve When the governor speed exceeds a certain revolution the governor pressure in the circuit

15

Oil from pump

also increases

j

i

as

the

centrifugal

I I

I

I I

Throttle valve

I I

II

Manual valve

How

Auxiliary valve

t t I I I I I

Line pressure

I I

L

L n

j

the governor pressure is transmitted to the circuil

I

I

force increases

and exceeds the governor pressure this valve moves toward the outside and

1

l

I

ever

Regulator valve

Speed change valve

I I

L

I

I

Governor valve

I I

1

L

5

Two different valves in the governor

so

are

j

employed

Clutch and brake

that it will inde

speed at high pendently and low speeds That is within the low speed range the governor pressure is not generated because of the primary control the

The control valve assembly receives oil

from

the

from

pump

the

and

vacuum

individual

diaphragm

valve whereas at the high speed range

signals

above

and transmits the individual line pres sures to the transmission friction ele

the

pressure is valve The

breaking point

regulated by

governor the secondary

breaking point

is the

point

one

at

of the

governor is transferred to the other the speed changes from the as

low

speed

to the

high speed range

changeover valves including ON valve and regulator valves are

newly reformed

to a throllle

system

and

oil pressure and operate other valves Finally the line pressure is transmilled to the required dutch or brake servo

lubricating system circuit as outputs More specifically the oil from the oil pump is regulated by the regulator

pisJon unit in response to the individu af running conditions after re ejving signals from the va uum diaphragm

line pressure build up the line pressure is fed out from the control

downshift

ment

which the function of

tion

OFF

valve

valve

torque

converter circuit

as

assembly through 6 AT

various direc

and

or

solenoid

manual

linkage

governor

dlvc

V

Automatic Transmission the line pressure

The control valve assembly consists of

the following valves

See

Figure

16

pressure

6

and the throttle 18

to

equal

is

AT 20 I

Pressure regulator valve

2

Manual valve

3

I st 2nd shift valve

4

2nd 3rd shift valve

5

Pressure modifier valve

6

Vacuum throttle valve

7

8

Throttle back up valve Solenoid downshift valve SDV

9

Second lock valve SL V

10

Manual valve

PRV

MNV FSV

converted

motion of

reciprocating through a pin and positioned so that the line

to

the manual valve

PMV VTV TBV

the MNV is

the indi pressure 7 is distributed to vidual line pressure circuits at each P

N

R

D

2

I

or

range

shown below

as

TMV P

range

7

regulator valve

Pressure

motion is

turning

The manual lever

SSV

2nd 3rd timing valve

MNV

4

SDV and TBV

5

FSV

Low

12

TBV and

reverse

brake

PRV R The

pressure regulator valve re ceives valve spring force force from the

created by the throttle pres

plug

force With

and line

16

sure

pressure 7 throttle pressure

of the

and

18

11

the interaction of those forces

orifice

20

depressed 7

port

As

shaped a

area

up to

R When the range is selected at 6 is Reverse the line

from

moves

applied

has also been

opened

result

the

is

oil the

oil in circuit

As

filled 14

above

6

PRY and SSV

F C

7

a manner

line

7

pressure

When

vehicle

speed

None

I

Governor valve FSV

and

rear

clutch

2

SLY

3

SL V and SSV

range

7

identi

I

Same

2

SL V

4

SDV and TBV

as

above 9 Band

applied

further in I

range

7

increases and

the governor pressure rises the theot tle pressure 18 is applied to the port the top of the PRV and pressure is applied contrarily against the spring

I

Same

as

above

4

Same

as

above

5

FSV

on

a

with

the line pressure 7 decreases Moreover at individual con force As

and this

further used for lubrication of

a

result

ditions the line pressure

unit Moreover part of the oil

rear

the plug in

10

the

ly

Ihe space

circuit

2

creases

from port 7 to the converter oil pressure 14 subsequent

is

range

caito the throttle pressure 16 and is added 10 the spring force Consequent

balanced with the spring force there by balancing the PRV In this opera

pressurized

D

pressure

such extent that the

converter

range

through

space to the next drain port marked X in Figure AT 10 with opens slightly Thus the line pressure 7 is

tion

N

Fig AT 10 Pressure regulator ualue

the PRV is

result

downward and

above

same as

AT095

pump is ap

from the oil

the ring

to

same as

5

7

driving conditions The oil

4

and band release

the PRY regulates the line pressure 7 to that most suitable for individual

plied

range

7

7

is

equal

to

1

Moreover 6

are

where

3

2

always drained the

line

tributed from

4 at

pressure

a

is

5

and

position not

dis

7

is branched and used for lubrication of

the front unit for the front and

rear

clutches When

presscd creases

Ihe accelerator

pedal

is de

u

the throttle pressure 16 in as described in the preceding

paragraph oil pressure the plug through orifice

is 21

applied

and this

pressure is added to the spring force As a result the PRV is contrarily forced upward is reduced

and

space to the drain Ihe

jd

to

P

l tJj

1dIil lt

R N

JJX

dlMIi W

fitMi td

ld

IiIb

j L@

g4Vhl 17 l It i

x

x

port

line pressure

B

J

jj

AT096

7

increases

Fig AT AT7

11

Manual ualvp

Automatic Transmission 1st 2nd

shift valve

high The FSV is

transfer valve which

a

shifts gears from low

second When

to

Ihe vehicle

is

depressed

the right side by force of

to

stopped

located

spring putting the position a

the

the

on

FSV

is

in

FSV

left

the

Ihe

15

pressure

is

side of the FSV

right

toward

the

returned

to

the left

the line pressure

I

Low

alled

is

This

j

1 c5

to

13

Contrarily

togelher with the

I

15

level

the

exceeds the

pressure and Ihe

governor sum

When the FSV

closed the

is

depressed

10

and only the spring

FSV toward

depressed

to

the right

I

a

Fig

the end for a moment As

AT 12

lsl 2nd

engaged through the SLY and the speed is shifted to 2nd With the

When the vehicle is

accelerator pedal

is

remains iIi the

depressed Low

the FSV

position unless

the governor pressure IS

increases to

high leVel corresponding to the line pressure I since the line pressure I a

increase when the accelerator

pedal

is

depresse9 Contrarily decrease shifted

Howeve f

to

pressure

governor

the

creases

when vehicle speed de

Low

the gear

15

is

not

nless the governor

pressure 15 becomes zero since the force depressing the FSV toward the

right

is

being

delivered

only by the

spring in range low and reverse

I

clutch

through

5

sure

2nd is end

line

simultaneousiy

is led

to

thougp creases

the

from line pres

prbssure led

to

12

the

spring unit Consequently

ieft al

the goverflor in pressure the valve is still forced toward

right

Low

shifts gears forced

is so

and the SFV is fixedjn the

position When kicked down to speed the SDV operates

2nd

and the line pressure 13 forces the FSV toward the right Although the

right by the

2nd

d however

design

the SSV

stopped

the

is in the

position It

that the FSV

decide to shift either

Low

to

or

2nd When the vehicle pressure

the right

end surface

the

is running

15

governor

is

and

forced toward the left

applied th

to

Contrarily

When vehicle speed exceeds a tain level the governor pressure

cee

sur

spring force line

the forces the force

SSV

the

toward

thus the SSV is end

for

depressed pressure pressure

leased

a

Con

being rapjdly depressing the

right decreases and depressed to the l ft

moment

With

Ihe

SSV

toward the left end lhe line 3

10

is connected with the line

the

band

servo

the front clutch is engaged 8 AT

is

re

and

line

SDV and

is led from the

toward

the right

high

the

is

forced

valve

loward the right

completely

2nd

to

tht

and

posi

fhis operation is called

K cli

down shift

iever

When the shift 2

I

or

the line pressure MNV and

shifted

is

range at the

3rd

to

speed

3

if diained at the

Consequently

the front clutch

band

servo

drained As

a

oils

releasing

are

result the transmission is

shifted

to

though

the SSV is in the

2nd

low

or

speed ai posi

3rd

tion

When the

specd IS

1 3r

way

a

topof

one

shifted io the

orifice

24

the

on

the SSV relieves oil transmitting

velocity from the line pressure 3 the line pressure shock generated

Contrarily to

2

I

or

10

fioni

drained

shifting

the

is shifted

range and the speed is 3rd to the 2nd the

orifice checking valve effective

to

and reduces the

when the lever

depressed

is then closed

shifting 3rd

at

siderably

line

unbalanced

3rd

to

is con

shifted from

sequently

2nd

is forced

pressure and throttle pressure and the valve is forced toward the left The

3

to

speed slightly lower

a

ure

the

toward the right

3rd

the governor pres

SSV is

line pressure 3 l force Spri and throttle press re 19 force the SSV

pressure

Shifting

slightly

a

Although

3rd

to

is returned

at

from

SSV is thus returned

SSV

2nd

toward

spring and can

from

passes the sum of the

Low

shift valve


a

position

13

SSV

the

tion

SSV is

the SSV

occurs at

pressure

2nd 3rd shift valve The

2nd

speed

shifting

3rd

When kicked down

AT091

is

while

applied

to

than that for

q

depresses

the resull line p ressure lJ is for to 8 the band servo is

a

warded

1

is

and it

2nd

the

I

r

the

I

position the lire pressure

from

2nd

t

of the throttle

is

right which

lower

FSV is forced toward the left certain

In the 3rd position force de pressing ihe SSV toward the right is retained only by the throttle pressure 16 and the throttle pressure 16 is slightly Idwer than that toward the

Consequently

a

pressure

spring force and

the throttle pressure 19 are high allll the SSV is thus retained in nd

to

0

certain

3rd

When the accelerator pedJI is de prcssed both the line pressure 3 and

unless the governor pressure 15 ex the line pressure 3 and the throttle pressure 19

the

When the vehide speed exceeds

is shifted to

speed

ceeds

15

the

FSV

Kickdown shift

spring force force the FSV toward the right opposing the governor pressure

the

the

position

15

and the FSV

is forced toward

is

operation

and

right the

low

applied

considerably

the valve is forced completely

side

When vehicle speed increases governor

is

is

15

governor pressure

FSV

the

throttle

the

spring

line pressure

quickly

and

24

is

becomes in

delay

in

10 is shifting

speeds is thus eliminated The throttle of line pressure 6 transmits Hie oil transmitting velocity from line pressure 6 to line pressurc 10 wtien the lever is shifted to the R ty

range

from

and transmits drain veloci line

pressure

10

to

line

Automatic Transmission 6 when

pressure

2nd

to

at

end readjust

generated the piessure loss is added to the spring force and the plug is lhus forced back from the right to the left When this pressure 19 increases ex cessively the plug is further depressed

which varies

toward the left

from

shif ing range

D

3rd

Thus

the

throttle of line pressure 6 reduces the shock generated froshifting A

in

plug

the throttle

depending

the SSV left piessu e I 6

on

engine

the

throttle

con

19

throttle pressure suiled to the sp ed change control Moreover the plug is a valve which applies line P esspre 13 in lieu of the dition

to

throttle

a

to the SSV and the

pressure

FSV when kickdowri is

space from the lhrot tle pressure 19 to the drain circuit 13 increases and the throttle press

balanced

19

Wheri SDV

the space is formed from 6 10 19 A throt throttle pressure 19 is lower by the tIepressu 1iFh w

drained

right

slight

a

pressure loss

equivalent

throttle

to

Ii

the

to

performing a

moves

speed decreases governor ipressure 15 de the force toward the fight

when the vehicle

rily arid

the

creases

governor

exceeds ithe

valve

is forced back

and

the

throttle is

valve

the

pressure

is led

pressure

are

line

pressure the toward the right 18

is

sWitched when

the

pressure

drained to the spring unit throttle

the

is reduced Contra

7

pressure source

and

high

both Tow

or

the

governor

when

tIiey

are

i

which had been

13

circuit

pressure

and the force of the line

the PRV

This

6

from

19

circuit

pressure

value

kickdowri

line

high

plug

is

pressure

certain

against the throttle pressure

performed

throttle

the

reduced

the

Thus

imd the

is

pressure 16 is applied to the left side of this plug and the plug is epressed toward the When

decreases

19

ure

18 This throttle 16to circuit pressure 18 is applied to the top of

i

the plug is forced toward the left and circuit 19 becomes equal to

11 I

16

18

the line pressure 13

to this space is

n

r

I

3

f

Jit

1

I 15

ng valve

Fig AT 14 Pre

24

15

3

Vacuum thro

I

I

The

regula

W

L

valve

Js

I i ilr

the vacuum dia

ATOgS

throt le

2nd 3rd

Fig iT 13

shift vallJe

the

pressure in When

plied

to

Odifier valve

PMV

When the governor

I

to the

operating pressure

Compared required in starting th vehicle ppwer trimsinitting capacity of is

required

at

high

to a

high

of the value and the spring foice

and

t

he circuit from

circuit 18 vehicle nor

pump loss also jncrdases In order to lrott pressure must le prevent his the t

hanged

over

is forced

ence

the

speed shock gerieraled from shirring increases arid the oil

l

the valve

the PMV is low

vehicle

be

IS

right side of

toward the right by the throttle ines sure 16 applied to the area differ

operating pres

level up

pressuie

the

When the line pressure is a

to the

applied

the

may be lower when the vehicle is

started

which is

with the operation

of

pressure

level the left

is closed

speed

circuit 16

15

to

However when

increases andl the

exceeds

gaver

a certain toward the

governor pressure applied to the right

which is

side

exceeds the spring force and the throt 16

the governor pressure 15 to reduce Ihe line pressure The PMV is used for

tle pressure

this purposc

the throttle pressure is led from

valve is

toward thc right the

depressed

depending condition

vacuum on

the

negative

inta e line

line pressure 7 is ap the bottom through the valve va

ve

is forced

upward

space from the line pressure 7 to the throttle pressure 16 is dosed and

I

Pressure

retained

a

line

the

the

hole and the 1

The

diaphragm

phragm yories

engine t

rH

once

uses

I

I

sure

VTV

valve is

7 for the pressure source pressure and regulates the throttle pressure 16 which is proportioned t the force of

l

r

clutch that

rottle

whiCh

AT099

modifier valve

le valve t

vacuum

tor

ure

loward the lefi and

AT 9

circuit

the space from the Ihrottle pressure 16 to the drain circuit 17 is about the throttle to open In this operation lower than the 16 becomes pressure

ureY btthe linep of the loss of s

alenl

p e space

sur

9

iv

and Ihe

if thevaeuum rod depressing tlie diaphragm is balanced wit Ii thethrot tie pressure 16 a pplied upward tOlthe force

bottom When the erigine

torque in the

negative pressure rises tending ioward pressure

is

high Ihe

intake iirie

atmospheric

and the force of the rod to

depress the

valve increases As

a

result

the valve is depressed downward the

Automatic Transmission space from the throttle pressure 16 to the drain 17 decreases and the space from the line pressure 7 throttle pressure 16 increases

Ihe

to

torque lowers and the negative in the intake line lowers

toward

vacuum

depressing

pr

tending

the force of the rod

the valve decreases and the

throttle pressure 16 also decreases When pressure regulated by the throt tle

p valve back

described in the

subsequent paragraph is led to circuit 17 a high pressure is applied through the space from the circuit 17 to the throttle pressure 16 Consequently the VTV is unbalanced 16

pressure

becomes

back up pressure locked upward

17

r

the

pressure

Consequently the throttle pressure 16 increases and the valve is bal anced Contrarily when the engine sure

to Ihe upper drain about to open back up pressure 17 which is lower than the line pressure 4 by the

17

circuit

4

with the

loss due to the space from to circuit 17 is balanced

spring force

Further 2nd

when gear is shifted from Low

to

at the range

pressure is led from circuit

I

line

12

and

the line pressure is applied the bottom of the valve valve hole forced

Consequently and

upward

pward

to

the

through

the valve is

locked

As

a

result the space from the line pressure 4

the back up

to

closed

is

17

pressure

and the back up is drained upward

completely 17

pressure

AT102

the throttle

equal

to

Fig AT 17 Solenoid

the

hift valve dow

Second lock valve

and the valve is

This valve is assists the


a

shift valve in

fixed

the

SLY

2nd

determining the

at

speed

2

range In the

D

force

spring

APplied upward 2

sure area AT101

difference

line

of the

pressure

applied

as a

sum

ds the

xce

which is

As a result

the

range

and

linepres

to the valve

downward force

the valve is locked

upward

and the circuit from line pressure Fig AT 16 Throttle back up

Jlve lJ

to line pressure

9 is

Consequently 2nd speed

the I

16

pressure

is

engaging

circuit

pressure

Solenoid

downshift valve

Fig

AT 15

AT100

Vacuum throttle valIN

when

Usually

is

TBY

depressed

downward by the spring force circuit 17 is drained upward As

soon as

and

the lever is shifted either

2 or I range line pressure is led from circuit 4 the line pressure is to

applied valve

to

the

area

difference of the

the valve is forced upward the from circuit 4 to circuit 17 is space closed and with the space from circuit

a

kickdown

signal

is

re

from the downshift solenoid

ceived

this valve


leads the line pressure 7 to 13 and transmits the same to the FSV and SSV

Throttle back up valve

a

Usually

the solenoid

valve

locked

are

rod and

upward by the spring

in the lower end

line pressure 4

push

and the circuit from

to

FSV

becomes

condition

the

and line

to

the

band

9

only when line

servo

is released to line pressure

1

In the

This valve is

2

is retained

the

range

only

on

upward

downward line pressure the

upward

As

2

exceeds

force

result

a

force

the spring and the

Ihe

valve is locked

downward line pressure 2 is released to 9 regardless of the operating condition servo

is

of the FSV

and the band

engaged J

line pressure 13 is

opened When kickdown is

push

rod operates

pressed

downward

from line pressure

performed

Ihe and 7

the

2

valve is de the

circuit

line pressure 13 opens Line pressure 13 opposes the governor pressure 15 at Ihe SSV and

FSV

thus

to

accomplishing downshift operation AT 10

8

opened

8

SDY

III

led

3

the

8

ATl03

3 Fig AT 18 Second lock

Jlve lJ

Automatic Transmission valve

2nd 3rd timln

TMV

the

force exceeds the down

upward

ward force the valve is locked This valve is switches orifice sure

the

22

a

by

transfer valve which pass

circuit

in the front

circuit II

of the

clutch pres

in response to vehicle

speed and throttle condition A force created

IS TMV

is

when

applied

the governor pressure to the bottom of the

constitutes the

upward

force

and passage from circuit l0 from

the

closed

Top

Consequently

to the top of the TMV consti

pressure

II

through

the orifice 22

However

under normal

throttle pressure downward force

applied

is

and the

oil pressure is thus transmitted slowly

force

the

the line

2nd II

is led to the front clutch circuit

exceeding

and

circuit

10

and a force created

when the spring throttle pressure are

to

upward

force

a

certain

As a result

tutes the downward force

downward

When the throttle pressure 16 is lower than the governor pressure IS

10

16

shifting

has

a

level

exceeds

the

the

pressure

and

the

upward

the valve is locked AT104

the passage from circuit to circuit II is opened and the

orifice 22 is

bypassed

ATll

Fig JlT 19

2nd 3rd

timing

valve


ern

I

n

d

lLU

J I A1094

1

2

Pressure regulating valve Manual val MNV

31st 2nd shift

val fSV

4

2nd 3rd shift

val

5

Pressure modifier valve

SSV PMV

8

Vacuum throttle valve VfV Throttle back up valve TBV Solenoid down shift valve SDV

9

Second lock valve

6

PRV

7

10

2

3 timing

val

SL V TMV

Fig AT 20 Controloolve AT 12


HYDRAULIC SYSTEM AND MECHANICAL OPERATION The operating system of oil pres in each range is described below

sure

The

oil

in

pressure

each

circuit

shown in the illustration is classified

as

follows according to the function fhe numeraJs show the circuit num Oil pump suction hole

bers

Pressure

source

of the line

7

Operating Iinc

prcssure for friction elements

ATl06

123456 8910 1112

Auxiliary

line pressurc

Fig AT 22 Identification of oil channels in

13

case

front face

Throttle system pressure 16 17 18 19 Others

14 15

I

Oil pump discharge hole 7

o

dischar hole

Oil pump

Torque

Rear

converter pressure

iutch

FTOOI c1 J1

Governor pressure 15

I9JM

Cd

Torque

7

tL h

prc

011 pump

14

ur

14

clutch pressure l Rear

1

surc prc

converter

pressure

It

Sllctlon

pressure

M

Os

ervo Ie I ease

pressure

0

10

Servo t ightening

0

IT U 11

Front clutch

hole

f

0

c1L

1 c

pressure

9

ho

lJ

I

I 0

rrOil J

r F T pump suction hol JC CJf

Governor feed pressure l

L

L

reverse

LIO

brake pressure

12

II O

An07

IIJ1iIII

AT105

Fig AT 21 Identification of oil channels in oil pump

Fig AT 23 Identification of oil channels in

AT 13

case

face

Automatic Transmission P

PARK

RANGE

The operation of clutches and band Neu are functionally the same as in tral

parking however when the parking pawl meshes in a gear which is splined to the output shaft the output In

shaft

locked

mechanically

is

from Lock

Free

rotating

AT086

Fig AT 24 Parlling mechanum

oil

The

pump is fed

discharged from to each

part

the oil a

CID through

circuit

valve

5 s

As

the

the line pressure 1st 2nd shift

to th force

right

actuates

the

low

and

Also

teeth of the oil distributor

by

of

the

manual

lever

locking the output shaft

Fron

Rear

brakt

Operation

2 132

on

the

r clutch

Neutral

PI Drive

Ihe

Lw

2

on

3

P2

Second

14S3

on

03

Top

1 000

on

on

on

on

on

outer Second

2

458 1

means

mechanically

Release

On

on

on

reverse

through the groove parking pawl engages with brake

ervo

on

er

hand ide

by the spring the line pressure 5 and 12

atia

Park

Re

Band

IlYer5e

N

has been introduced into the manual I st 2nd shift valve Il reaches the valve

Range

Low

Clutch

Gw

similar

range The oil having the line pressure 7 which manner

to that of the

in

12

Second

1458

II

Low

453 2

AT 14

on

Parkin

pawl


Park

range

A

L k r

k

8r ll FrOl ter Con

Torqu

I

Au

Clutch

tth

0 I

ump

rr

4

f

1

1

r

I

I

r I 011 Coo

I AM

Lubr

i t

n

TIlro V

v

v

t

1 j

1111

il

III

l

n rt

1ft

lv

Front

o

to Sol BI Cow

VK

II

D V

I

1111

tlo

CID

I

r

Llrll

I Orlflc K

v

Throttl Dr ln v

2

ID

Mocl

1

5

II

11

@ I

J w

5

2nd 3 V l

d

Timing

JQ

I

r R 3J I

IKOnd

Lock

I

II

D tOl V

V

L Not

q

I nu

V

u

l

P

21

I Or

LlMl pr

J1

r A

I

J I

1

BIeOM OOll

I

IV

nor

Oo

rr

J ll

n

ln

10010r r

J2

3

l

II

t rk

l

II I l

I

t rJ R

V

Y

M

rlmarv OoverrwJf VIIfve

or It

Torqu

conv

ner

Throttl

Fig AT 15

A T 25 Oil

circuit pressu

diagram

P

range

Parh

Automatic Transmission RANGE

R

R

In

REVERSE

range

the low and

R

the front clutch and

reverse

brake

applied

are

The power flow is through the input shaft front clutch and connecting shell to the

sun

tion of the

sun

Clockwise

gear gear

clockwise rotation of the the

With

ry gears

planeta

rear

connecting drum

held stationary by the low and brake the

the

rear

rear

rota

counter

causes

reverse

gears rotate

planetary

internal gear and drive the

flange counterclockwise The drive flange splined to the output

rear

shaft

rotates the output shaft counterclock wise

at

reduced

a

increase in torque for

speed reverse

with

Fig AT 26 Power tranamis ion during

an

R

range

gear

m

i

1 ATOBS

Fig A T 21 Optrationof each mechanism during

When the manual valve tioned at

R

line pressure pressure

V

is

posi Gear

range the oil having the 7 is directed to line

circuits

5

and

6

Ranae

ralio

Low

Clutch

Band

One

servo

re ne

Front

Rear

brake

way

Openlion

Relulie

clutch

into line pressure circuit through the I st 2nd shift valve

Park 2 182

Ruene

on

on

on

servo

led

DI

Low

2 458

on

D2

Second

1458

on

D3

Top

1000

Second

1458

on

on

12

Second

S8

on

on

II

Low

2 458

on

and the front c1u tch after to

through

line the

circuit

pressure

2nd 3rd

being

shift valve

CD and press against

its valve

Driowe

0

@

degree of accelerator pedal depression both act on the pressure regulator

2

CD

increasing line pressure 7 In Rn range the governor pressure is absent making all such valves as the shift valve

@

on

the release side of the band

The throttle pressure I 6 and the line 6 which vary with the pressure

valve

Neutral

The pressure in the circuit op

erates

ID

and pressurc

lnd 3rd

Partina plwl

on

on

introduced

ID

range

The

pressure in the circuit 5 actuates the low and reverse brake after being 12

R

1st 2nd shift valvc

modifier valve

inoperative

AT16

on

on

on

on

on

Automatic Transmission R

range

Reverse

Low Br

Con Torq

Front ltc Cll

a

Aev

k

k

B

I

R

Il

Clutch

f

r

III

rr

I

CID

VEL 1 Thrc V

Oil Cool

I

1 11

I A

Lubtlcetlon r

0

o

or ln

Vel

iL

l

n

I

IU

111

11

T

Ilrfl

Ir l

I

II

II

Front

jL

r I

r

r

r

Orlflc

LJ

Check

Velve

Throttl D

ln

2f

v

ID

@

l 2nd 3n

J lf

v

If I

@lnd

n

22

e Mc

p

3rdShlft v

D

h

I 1i t

lil Timl

x

II 5 r

Q A uletor

U

Val

nu

r 1 NIJte

L

kld

Ll

ni l3

II

O

nOl

ft

p r

a Goy

nor

v

Q

V

1ve

l norpreat

Torque Throttl

15

eln

O

p

15

rmrp p

Fig AT 17

A T 28 Oil preBBure circuit diagram

R

range

Reverie

Automatic Transmission N

RANGE

In

N

and band

range are

transmitted

NEUTRAL

none

power is the output shaft

applied

to

of the clutches

thus

Geu

no

R

atio

Low 4

Clutch Front

Rear

Park

the

The pressure of oil discharged from oil pump is regulated by the

pressure regulator valve Dto maintain the line pressure 7 and the oil is led to the manual valve @ vacuum throt tie valve valve

@

@

and solenoid down shift converter at its

torque erating pressure 14

and

a

op

portion of

this oil is distributed to each part as the front lubricant The oil which has been

from the torque con verter is also distributed to eacn part as

the

discharged

2 182

WI clutch

on

Drive

on

on

Low

2 458

on

D2

Second

1458

on

on

m

Top

1000

on

on

Second

1458

on

on

12

Second

1458

on

on

II

Low

2 458

2

discharge increases with engine speed oil is returned to the

oil pan by the pressure regula tor valve

D

AT la

on

on

on

on

Pultin pawl on

Dt

rear lubricant

surplus

Release

Neutral

As the oil pump rotates at the same speed as the engine the oil pump But the

Operation

on

Reverse

The oil is further introduced

into the

brake

One

Band crvo

on


range

Park

1 Brllk ar Con

Torqu

Front Cluteh

u

Bond

o

ID

VK Th V

all

o

I

IftY

II

Coo

A

k tlon Lb

II

e 1

I

Front LubrkIt

n

Orltlc Check

O

ln

V I

ThrOttle D ln V

21

j r

tUI

lor

V

h

@

V

hI

5 I

N01

M

rked X

Line

r

D

I

ln

pr Go nor td

pr

I no Ocw

J L J c

Q

RO

V

Gover

V

p

Torq Th ottl

X

y Iecond

co

p

f

p

Fig AT IS

A T 25 Oil pressure circuit diagram

P

range Park


RANGE R

In

REVERSE

the low and

R

the front dutch and

range

reverse

brake

applied

are

The power flow is

shaft

through the input clutch and connecting

front

shell

to

the

sun

tion

of the

sun

gear Clockwise rota causes counter

gear

clockwise rotation of the

rear

planeta

the connecting drum held Slationary by the low and reverse With

ry gears

brake the

the

rear

planetary

rotate

gears

internal gear and drive the counterclockwise The rear

rear

flange

splined to

drive flange

the

C

output shaft

rotates the output shaft counterclock

wise

at

reduced

a

with

speed

increase in torque for

reverse

Fig

an

AT 26 Power transmi

ion

during

R

range

gear

f

ATOS5

Fig AT 27 Operation attach mechanism during

When Ihe manual valve tioned

R

at

Ihe oil

range

line pressure 7 pressure circuits

CV

is directed and

5

is

posi

having 6

introduced into line pressure circuit 12 through the I st 2nd shift valve The

servo

led

and the front clutch after to

through

line the

The throtlle pressure 6

pressure

being

circuit

10

shift valve

@

pressure

2nd 3rd

16 and the line

which vary

with

1 181

Rdr ue

clutch

plwl

on

on

Driw

on

D2

Second

1458

on

on

DJ

Top

1000

on

on

Second

1 458

on

on

12

Second

1458

on

on

II

Low

2 458

on

2

on

on

I

shift valvc

pressure modifier valve

on

on

1 418

the governor pressure is absent making all slldl valves as the J SI 2nd

@

Operllioo

Low

range

2nd 3rd

brake

DI

CD and press against its valve CD In R increasing line pressure 7

@

Rear

Neutnl

valve

and

Front

Parkin

wa

on

Revctte

the

degree of acceJerator pedal depression both act on the prcssure regulator

shift valve

One

servo

no

k

pressure in Ihe circuit op release side of the band

the

erates

ratio

Band

range

The

pressure in the circuit 5 actuates the low and reverse brake after being

@

G

Ran

line

to

Low A

Clutch

Ihe

R

j

inoperative

AT 16

on

on


Reverse

range

LowaoA B e B

Front Clutdt

TOlQuaConverter

k

k

Clutch

0

o

ou

IIi

14

Q ID

VK

V

FI

Lu

IUt

@

n

ftV 1

lv

I

O

j Front Lub

O

lnV

lc

Otlflce Check V

ly

III

Throttle in

O V

@lnd

3rdShih V

zz

If

@

2nd V

rd

TIm

Iy

Second

Lock

V

I

3

Zl R

MO

V

l

Not

M

LI

dX k

er

0

1

O

p

nOf

f

P

co s

O G

J Torqu I Throttl

0 V

O

V

preau

00

p

pr

1

Fig A T 28 Oil pressure circuit diagram AT 17

II

n

range

Reverse


RANGE

In

N

range

and band

are

transmitted

NEUTRAL

none

applied

to

of the clutches Low

Clutch

thus no power is

ntlo

the output shaft

The pressure of oil discharged from oil pump is regulated by the

pressure

regulator valve

the line pressure 7 to the manual valve tle valve valve

@

@

CD to

Rur

its

at

erating pressure 14

portion of

op

this oil is distributed to each part as the front lubricant The oil which has been verter as

the

Drive

The oil is further introduced

into the torque converter a

from the torque con is also distributed to eacn part

discharged rear

Release

clutch

2 182

on

on

on

01

Low

2 458

on

02

Second

t458

on

on

03

Top

1 000

on

on

Setond

1458

on

on

12

Second

1 4 58

on

on

II

Low

2 458

2

on

on

1

lubricant

As the oil pump rotates at the same

speed as the engine the oil pump discharge increases with engine speed But the surplus oil is returned to the oil pan by the pressure regulator valve

CD

AT 18

on

on

Pukiq pawl

on

throt

and solenoid down shift

and

Optruion

1 Neut

and the oil is led

V

br ke

on

Reverse

maintain

vacuum

One

servo

w

Front

PIlIi

the

Band

G

R

on


Neutral

ranee

I

a a

8 nd

VK Th o Vtlv 011

Coolei

Lubrlc

J

@

Vtlv

I I

tlon

11 D

ln

I

v

Ol

OIIt

Lubrlut D

lnV

O lfIC Check Vtlv

I

T

uott

O

in

v

8Jl 12 ht 2nd Shift y

tve

5

CD Rl9UlttO

Vtlv

Nott

M

rkedX

1

or

no oov

z c

liia

in

IOonOf

fNd IH

cs ond a

y

Ol

V

o

V

tve

p

er

Torqu Throttl

D r

con

pr

p

Fig AT 29 Oil pressure circuit diagram AT 19

N

range

Neutral

Automatic Transmission D

RANGE

The

low

LOW GEAR

in

gear

D

is

range

somewhat different from that in

I

range The I

c1utdl is applied as III the one way clutch

rear

but

range

holds the connecting drum The power now is the same as in 1 J range That is the power now takes place through Ihe

shaft

input

and

into

the

rear

clutch

The input shaft is splined to the rear clutch drum and drives it Rotation of Ihe rear clutch

clutch drives the

rear

The front internal gear front

planetary the

cause

sun

clockwise of the

ATOSO

hub and front internal gear

gears

rotales

the

clockwise

to

Fig AT 30 Power transmission during

DJ

range

to rotate counter

gear

Counterclockwise rotation

gear turns the rear planetary gears clockwise With the rear plane carrier

tary one

sun

held

stationary by the

way clutch the clockwise rotation

of the rear

rear

planetary

gears rotates the

internal gear and drives the flange

clockwise The internal drive

is

flange

to the outpul shaft and the output shaft clockwise

splined

liIIl

I

IW L

rotates

AT08l

Fig AT 31 Operation of each mechanism during When tioned

the

manual valve

is

at

3

posi

The pressure in the circuit

1st 2nd

shift valve

The

circuit

second lock valve actuates the

for the at

same

2

leads

@

change to

The circuit shift valve

pressure I SI 2nd

circuit

is

3

@

pressure

16

CD

Orivt

ch lch

Parking pawl

2 t82

on

on

on

on

01

low

2

S8

02

Second

1 458

OJ

Top

1000

Second

t2

tt

on

on

on

on

on

on

1458

on

00

Second

1 458

on

on

low

2 458

on

I

actuates

CID

the

2nd 3rd

@ and pressure modifier When the governor pressure the pressure modifier valve ID direction

as

on

on

t

and increases the

introduced from the line

a

Rekase

which

ID

high

way

Operation

Neutral

locks the second

shift valve

acls in such

brake

the

shift valve valve

Rur

on

RellerK

the

line pressure 7 When Ihe speed of the vehicle has increased the governor 15

Front

Park

changes with the degree of accelerator pedal depression presses Ihe pressure

pressure

On

servo

I

2

regulator valve

Band

speed change and

lime

throttle

low Rllelle

ratio

@

lock valve The

to

2nd 3rd

2nd 3rd

the

CID

Clutch

Cur Ran

acluates the rear clutch and the gover nor and al the same time operates the

speed

range

D

the line pressure 7 introduced into the manual valve is led to the line pressure circuits l 2 and

VJ

to compress

the spring and the throttle pressure is led to the throttle pressure 18 This

against the force of the pressure regulator valve CD and also against the throttle pres sure 16thus lowering the line pres pressure acts

spring of the

sure

7

The governor pressure also increases with the speed of Ihe vehicle exerting a

on one side of the pressure lst 2nd shift valve and counter acts

the Ihrottle pressure

19

AT 20

line pressure

on

l and the spring which are exerting against t 1e governor pressure There fore

when the governor pressure ex ceeds Ihis pressure the speed is shifted from the I st gear to the 2nd gear The further the accelerator pedal is

depressed

the

higher

becomes the

19

increasing the

throttle pressure governor

pressure

speed change point

and to

shifting the higher side

the

Automatic Transmission 0

range

Low

gear

L

A

e B Front

I

Conven

Torque

Clul Clutch

6 I

Q TIC

011

p V

ID

v Th O V

011

Cool

RUf

LubtJuflon

n Ii

IO lln V

l F ont

Lub D

nV

lclt

Orifice

n

V l

ThroW

L

01 V I

13

t 12 tt

llttY 2NtSt

5

Q

P

P

tOO

V

Note

U

X

Ir

no GoY

Torque Th

or

n

nor feed

IO

Llnep

Iecotodary nOl V QoY

i

Y roo Oew

v

p

co

p

on


uD 1

range

Low gear


RANGE

In

this

2ND GEAR the

case

h

rear c1ut IS the band brake the and holds applied

fronl

h drum dUh

the

connecting

gear from rotating The power flow lakes place through the input shaft into the rear clutch and shell and the

the front

sun

internal gear With the

sun

gear held stationary the front planeta ry gears rotate around the sun gear

planet

carrying the front them

The fronl

splined

the

to

carrier with

carrier

planet

being

shaft

output

causes

clockwise rotation of the output shaft at a reduced speed compared with the

t

of the

speed

increase

with

the

As

torque

brake is not

reverse

wise

in

input shaft

Fig

AT 33 Power transmission during

Dz

range

an

low and

applied the clock

rotation

of the output shaft clockwise rotation of rear inter

causes

nal gear and the rotates

rear

around

clockwise

planet

the

sun

direction

clutch will

act

rotation of

carrier also in

gear

The

one

a

way

to allow the clockwise

connecting drum AT079

Fig AT 34 Operation of each mechanism during

Low

Clutch G

Range

ratio

Fronl

Rur

running

D

at

st 2nd

speed

increases while

range

shift valve

ID

ing the line pressure I duced

into

the

line

I st gear moves to

be intro

pressure

clutch

2 182

on

on

Drive

8

on

on

01

Low

2 4S8

on

02

Second

1 4S8

on

on

OJ

Top

1000

on

on

Second

14S8

on

on

12

Second

14S8

on

on

II

Low

2

on

1

AT 22

4S8 2

on

on

Patking pawl

on

Neutral

the

through the second lock valve @ and by locking the band servo obtains the gear condition

Optrltion

allow

Ihrough itself The line pressure 8 is further led to the line pressure 9

2nd

w

Release

on

Revtne

car

brake

range

On

servo

reverse

PlIk

When the

Band

D

on


ran

e

2nd

ear

I

I

7

I

l

Throttle k up

ftV

V

II

I

ont

Lubtlclt

Orifice

n

CKk C

alnV

I Val

Th ottle O

2

n

S

V

Mod

l

IS

Valve

13

@2rlCl

3 dShlft V

13

F

311ft

2nd Shift

V

l

S

CD Regulator

V

Manual V

PR

Nota

M

X r

Dr

nor IGov

LI p

norp Gov

J c Iiiiiiiiiiiiiii

00 TORI

fINd P

ieconoery Gov nor V

I

n 1 i

O

nof Vaw

r

pr

Thronle pr

Fig AT 23

A

T 35 Oil pressure circuit diagram

D

z

range

2nd gear


RANGE

In

TOP GEAR

OJ

a

3rd gear

position the front and rear dUlches are engaged The power now takes place through the input shaft

into

clutch

rear

drum of the

plates

clutch drum The

rear

The

rear

rear

drive

steel

clutch and the lined

drive plates of the lined drive

the

rotates

rear

clutch and the

plates of the front clutch

clutch directs the power flow the rear clutch hub and front

through internal

gear

the

to

front

net

pl

carrier

The front clutch directs Ihe power through the connecting shell to

Fig AT 36 Power transmission during

now the rear

sun

gear Wilh the hub

clutch

the front

speed

rotate

the

the

speed

in the

same

the

at

same

planet assembly

forced to

range

gear and the

sun

driven

DJ

output shaft direction

is at to

provide the top gear

A T083

Fig AT 3 the

When creases

while running

2nd gear

15

at

D2

exceeds

em

range

shift valve

and the throttle pressure

2nd 3rd

shift valve

@

19

moves

the

8t Ral

ratio

Low

Clulch

Band

One

KrVO

w

reverK

Front

Rear

brake

Operation

Rdene

Reverse

2 182

on

on

on

Neutral

Drive

on

01

Low

24S8

on

02

Second

14S8

on

on

03

Top

1000

on

on

Second

t 4S8

on

on

Second

1 458

on

2 458

on

10

1

12

on

on

t I

Lo

AT 24

on

Parking pawl

on

on

Park

range

clutch

and

the line pressure 8 acts to release the front clutch and band servo through the line pressure

hani5m UDJ

force of

the combined

2nd 3rd

mf

in

and the governor pressure

the spring of the

@

speed further

car

Operation of aeh

on


range

Top

gear

A

Low lI eke B

e

I I

D VK

J

mf

Thro V

V

011 COO

va

J

Lubfkatlon

R

y o

Ot al

oi

v

L Front Lubric

1

Oriliu

n

Check

O

nV

1 1

Th onla

P

M

lflM V

2

O eln

I

5

Vah

22

x

i2J 3

j R

1n 2nd

Shift

v

1Ye

5

Pr I

Of

1

1

Manue Val

5

PRND2

r Marked Dr

Nota

11

ln

IOono

feold

P

Oo no

p

c

Torq Th onl

on

rs l

ond y

G

nor

y

Val

Goy

rnor

Val

np

pr

Fig AT 25

A T 38 Oil pressure circuit diagram

uD J

range

Top gear

Automatic Transmission RANGE KICKOOWN

0

operating

While

80

appruximately 55 MPII

a

pressing

3rd lst can

also

or

be

approximately

fully

t f

2nd lst

to

from

2 82

Opcullon

Release

clutch

performed

the

Drive

the

02

low

cond

2458

on

1458

on

on

Second

1 458

on

on

low

2

t ooo

Second

12

tl

2

3rd 2nd

downshift

the

hne

the force of the

pressure lst 2nd

op

13 shift

valve spring oppose the governor pres I st 2nd shift valve at the sure 15 and thus st

perform 3rd 2nd operation

on

t

eration Moreover

on

on

on

Top

D

on

on

1 458

15 thc governor pressure 2nd 3rd shift valve @ and thus

performs

on

on

on

or

downshift

AT 26

4

8

on

on

pawl

on

Neutral

Dt

the

2nd

brake

lnl Parll

w

50 kmfh

at

ID

On

servo

on

Reverse

hne pressure 7 to the hne pressure 13 opens The h e 3 plus the force of the press e 13 2nd 3rd shift valve spring oppose

plus

Rear

Park

push rod operates by the solenoid the valve is depressed downward and the circuit

Band

de

accomplished

40

When kickdown is

r

Fronl

downshift

by

La ltr5e rf

e

nUo

25 to 30 MPII

f

Clutch

Cur Ran

the accelerator

downshift below

speeds below kmfh 50 to

3rd 2nd

kick

kick

A

90

accomplished

be

an

at

to

on


0

Shift valves In 2nd gear position

kickdown

range

Low a

A

8 8 Front To

queeO t

e

e

a

Clutch

o 14

0 7

VK Th V Oil

Throttle

ID So

BKk up

o

V

lv

e

COw

1 iftV

8

hl

COO

R

Lubrication

n Drain 0

j

4 1

v

I

Front Lub icet

P

Ifk

Check

p

o n

V I

I

Thron

24

p ain V

5

Mod

Yo

I I

@2nCl

lilr 3rdSl V

12

3

j gu R

ato

V

ht 2nd

Shih

V

5

I I

1

M

I

0

r

J f4fL

nual

PR

L Not

Ma

Li

ked X r

pr

p

I

n

IGo

no

fd p

l

COnd S

G

rw

Va

X Primary Gov

norValve

Governor p

c

Torque CO

I1

p

ThrOWepr

Fig AT 39 Oil pressure circuit diagram AT 27

D

ronge kickdown

shift values in 2nd gear position

1


RANGE

2ND

GEAR

In 2 range the gear rario is IOI keJ the 2nd forward speed In this case

III

the rear dutch is engaged and the band brake holds the front clutch drum the connecting shell

and

sun

from

gear

rotating The power flow takes place the

input shaft

and

the front

sun

gear

with them

being

clutch

stationary

Ihe

the front

gears rotate around the sun the front

carrying

gear

through

rear

internal gear With

held

planetary

inlo the

The

splined

front

planet carrier planet carrier

AT078

the

to

output shaft clockwise rotation of the OUI

causes

put shaft

at

a

Fig AT 40 Powu tTansminion during

2

H

range

reduced speed compared

the speed of the input shaft with increase in torque As the low and

to an

brake is

reverse

wise

not

rotation

causes

engaged the clock

of

the output shaft clockwise rotation of fear inter

nal gear and the

rear

around

rotates

clockwise clutch

planet

the

sun

direction

will

act

carrier also

one

allow

to

in

gear

The

a

way

clockwise

rotation of connecting drum

A1079

Fig AT 41 Operation of each mechanism during When the manual valve tioned

2

at

V is

the line pressure

posi 7 is

is led

I and

the governor

to

I st 2nd

of

shift valve

rear

CID

clutch

as

2 is

led

band

thc

tightening

2nd

gear

of

regardless

high pressure in the circuit 17 increasing thc throttle pressure li 6 7

pressure

increased

and

is

quickly

brake

Release

Parking

Operalion

dutch

pa

on

2 182

on

on

on

Neutral

Drive

01

Low

2 458

on

02

Second

1 458

Oft

Oft

OJ

Top

1000

on

on

Second

1458

on

Oft

12

tocond

1458

tt

Low

2 458

1

a

line

Rear

on

When

speed

DJ range 3rd gear is shifted to 2 range the line pressure 4 enters Ihe throttle back up valve V and produces

The

On

o

side of Ihe

is therefore fixed

vehicle

ser

on

e Revtrs

servo

The

Front

Pui

D

to

Band

w

utio

range

in the

range The line pressure locks the second lock valve @and

case

Ran8t

Low

Clutch

Gw

introduced into the line pressure cir cuits I 2 and 4 The line pressure

2

on

on

on

J

therefore

tightens

on

on

on

the

band

2 sure

N

DJ

e

range

3rd gear

to

2

range

If

DJ

to

2

manual

position causing the circuit

range valve

3rd gear

is shifled

during operation

V is

the

also shifted to

be

to

line pres

drained

the line pressure circuit

Therefore

10 which range

3

is situated at the release

side of the front clutch and also drained

shift val

e

through

the

@ forcing AT 28

servo

is

2nd 3rd

the speed to

decrease from gear

3rd gear to 2nd In this case the speed change

quickly pressure

takes 7

heightened pressure

4

place because

the line

and other pressure are by the action of the line in the

described under 2

same

manner as

range


2nd gear

range

l

A

ow

B

ke

Br Fron

Torqu

Con

I

Clutch

12

i

12

ID IL 011

7

v Th ot Valve

T

ID

onl

Beck up

Id

So

1ft v

0

V

Cool

Front Lubric Or

Orltic t

Check Va

e lnVal

Va Modif

P Throttle Dr

15

in

V

l

BJl If

@

2nct 3rd

Tim

Ve

12

3

1

2nd Stolt

21

Se

l onc Lock Va

I

3

J I

A

r

ul

Gr

v

2

w Valve

PR

Note

Merltedl

Line

a

D

02

Jl I s

1

n

nOf f d pr IOo

p

ond

a G

no

p

oTorque c Thron

con

p

nor

v

I G

v

r

pr

re


2

range

2nd gear

Automatic Transmission RANGE

1

LOW GEAR

Wilen

I the slJrting in range gear is IOlked to the low gear

drlvlIlg fJIIIJ

H

In

the

range

hulds

reverse

brake

he

onnecting drum and from rotating tlow lakes place through

planet

feac

carrier

power

input shaft and

into lhe

is

clutch

rear

and the low and

engJged

The the

clutch

rear

ROlalion of the

rear clutch drives lhe dutch hub and front internal gear The front internal gear rotates the rear

front

C

planetary gears the sun gear to rotate counter clockwise

cause

AT076

to

clockwise Counterclockwise gear turns the clockwise sun

The

Fig AT 43 Power transmission during rotation

planetary

rear

1

range

J

of the gear

Fai1

planet carrier splined to connecting drum is held from rotating by the low and reverse brake rear

the

The clockwise rotation of the

f

rear

planetary gears therefore rotates the rear internal gear and internal drive The internal drive

tlange splined

to

tlange

the output shaft and

is

rotates ATOn

the uutput shaft clockwise However the output shaft rotates at a lower

speed compared

to

that of the

Fig AT 44 Operation of each mechanism during

shaft This is caused by the fact Ihat the front planet carrier rotates at the same

speed

same

direction

splined

to

since

but

carrier

the

planetary

rotating in the the planet carrier

are

front

Low

Front

Rur

Park

Band

On

servo

Parking

w

Release

Operatlon

brake

pawl

clulCh

on

Reverse

gear assem

same

and

rear

range

is on

2 182

on

on

on

direction Neutral

is

rotating at a speed slower than the ring gear So the gear ralio of this speed range is a combination of the ratios provided by the

Clutch

reverse

ratIO

the output shaft The front

internal gear and

bly

Gm

Range

Ihe OUlput shaft in the

as

JJ

input

planetary

gear

01

low

2 458

on

02

Second

1 458

on

on

03

Top

1000

on

on

Second

1 458

on

on

2

Second

IAS8

on

on

1

low

Drive

as

on

on

on

semblies 2

I

When the manual valve tioned at

applied I

4

actuates

I

Vis

the line pressure

posi

the

7

pressure

is

into the line pressure circuits and 5 The oil pressure in 5 the

luw

and

reverse

brake

after being introduced into the circuit 12

ID

through and

Ihe

1st 2nd

the line pressure

rear

in

2

4

The line

acts in the same manner as

range

line

to

pressure

reases inr

D

range

with the

degree of accelerator pedal depression and

I

the increase of car

the

on

15

pressure I st 2nd

which

acts

shift valve does

on

not

the

increase

until it overcomes the combined force

that of the

shift valve acts on

on

clutch and governor

Similar the

458 2

line pressure

decreases with

speed The

AT 30

governor

of

the

spring cha nge

line

pressure

causing

no

12 st

2nd

and

the

speed


1

range

Low

gear

ift Down Oid llll

14

@50

VK Th

10

I

D

o

IttV

v

il Dr

in

14

I

Front Lubrlc

O

mV

I

Oritlc ChKk t

V

i

P

Modif

Th on 0

t

IS

1 11

V

1M 2nd

hlf

23

J 6 g

M V

nu

l

PR

i NOI

M

11

keel X

Ir

0

nOt IOov

P

I

1 11

tMod

P

s ond O

O

no

Torqul Tn ont

V

I

V Oov Of 1

v

p

con

pr

pr

Fig AT 31

A

45 T

Oil pressure circuit diagram

II

II

range

Low gear


2nd

ran

ar

L

l ak

v 0

ou

r

Coo

L

O

fi

u

Co

nro

O

So

h OId

v Th o V

IhV

we

UIIoft

ein

iv

Lubolcat

0

OtHIc CO

v

v

Tlwont Q

MOdIf

in

v

1 0

V

h1

joy

ll

v

iJl

N

8I1l

L1

a

0

1

10011

p

0 fd P

lli Onct a v nor

Y 0

V

no

Torq Th on

conv

pt

Fig A AT J2

46 T

Oil pr

ure

circuit diagram

1

z

range

2nd gear


REMOVAL AND INSTALLATION CONTENTS ASSEMBLY

TRANSMISSION REMOVAL

AT 33

INSTALLATION

AT 33

ADJUSTMENT

8

ASSEMBLY When

transmission from

the

a

automatic

vehicle

at

pay

following points

dismounting the trans mission rigidly inspecl it by aid of the and dis Troubleshooting Chart mount it only when considered to be Before

necessary 2

Dismount

utmost

the

observe cated

on

the transmission with and

care

tube

vacuum

and wire

diaphragm

from

connee

when

mounting

tightening torque indi

another table

not

to exert

Disconnect

9 from

speedometer

10

Disconnect oil charging pipe

II

Disconnect oil

12

Support engine under

oil

Note

by locating with

pan

a

Plug up the opening such as oil charging pipe oil cooler tubes

a

wooden

INSTALLATION Installation of automatic transmis

block used between oil pan and jack Support transmission by means of a

sion

transmission

removal However observe the follow

jack

Detach converter

13 cover

Remove bolts to

housing

dust

ing installation

securing torque See Figure

drive

cating against plate

Replace 0 5

In dismounting automatic transmis sion from vehicle proceed as follows

ground

order of

reverse

notes

Turn crankshaft measure

REMOVAL

is

Drive plate runout

plate

drive

vehicle

on

plate

finger of

Disconnect battery

be removed and

etc

case

4 AT

I

can

take out transmission under the car

cooler inlet and

outlet tubes at transmission

jack

AT 35

rear extension

converter

excessive force

cable

AT 35

bolts support engine and transmission with jack and lower the jack gradually until transmission

lions at downshift solenoid

dismounting

tention to the

Disconnect

vacuum

AT 35

CONTROL LINKAGE


TRANSMISSION

1

TRANSMISSION

AT 33

mm

See drive

a

one

full turn and

mnou

t with indi

dial gauge

Figure plate

rested

48 AT if in

excess

of

0 020 in

Maximum allowable mnout 0 3 mm

0 012 in

cable

from terminal

Disengage torsion shaft from celerator linkage 3 Jack up vehicle and support 2

ac

AT261

its

safety stands Recommend a hydraulic hoist or open pit be utilized weight

on

Fig AT 47 Removing torque conv rter attaching bolts

if available Make 4

sure

Remove

that

safety

propeller

is insured

Note

shaft

Before verter two

Note

Plug

up the

opening

removing torque

parts

replaced

in the rear

con

scribe match marks so

that

in their

on

they may be original posi

A T262

Fig AT 48 MeCJ uring drive plate

tions at assembly

runout

extension to prevent oil from

flowing

out

14 5 6

securing

Disconnect front exhaust tube

Disconnect

selector

range

lever

Disconnect

inhibitor switch

wire connections

at

bolts

rear

and

engine

mount

crossmember

mounting bolts 15

from manual shaft 7

Remove

16

Remove starter motor

securing transmis After removing these

Remove bolts

sion to

engine

AT 33

2

Installation

of torque

converter

Line up notch in torque converter with that in oil pump Be extremely careful not to

parts See

in

cause

installing

Figure

49 AT

undue stresses in

torq

e

converter


Bolt

4

converter to

drive

plate

Starter should be

brought

into op

eration only when selector lever is in P Note

S AT116

Fig AT 49 Torque aligning 3

When

verter

to

tan

A

connecting transmission

torque

d S mbi

correctly

t

can

measure

to be certain that

cu

dis

they

are

painted a cross both parts during disas sembling processes

crankshaft several turns and check to sure

that transmission rotates freely

without binding 6

Pour

fluid up to correct level

through oil

charge pipe

7

Connect

More than 215

mm

0 846 in

8

I

manual lever

to

shift

and selector

levers

in

positions

it should not

R

D

2

positions

Back up lamp should also light when selector lever is placed in R

position 10

in transmis

Check level of oil

sion

For detailed procedure

see

page

AT48 II

Move selector lever through aU to be sure that transmission

positions

engine

the

correctly hand

above

through felt

brake

applied

Without

idling

at

and to Connect inhibitor switch wires

N

and

With

N

A

and

be started when lever is in

operates

rod Opeiationsliould oecaTrie fbue with manual

Distance

automatic

recommended

transmission

F

AT 50

marks

After converter is installed rotate

be converter

Align chalk

rotate

disturbing lever

sclUng ffiovTSelector N

R

D

to

A

slight

2

to

to

I

shock should be

by hand gripping selector each

time transmission is shifted

A

Notes

a

Refer

under

covering topic Checking and adjusting

inhibitor

to

switch

Note

See page AT 49 for

checking

engine idling

n

on

page

AT 49

b Inspect and adjust above whenever it

switch

as

has to be

removed for service ATl17

9 Fig AT 50 Installing torque converter

Check inhibitor

eration

switch for op

12

Check to be

that line pres refer to relative topic under Testing line pres sure on page AT 52 sure

13

is correct

Perform stall

instructions

AT 34

on

sure

To do this

test

as

page AT 50

per

the


TRANSMISSION CONTROL LINKAGE

4

j B

120N L p

r G

4

AT273

Tightening torque 1 nuts and screw kg m

1

Control lever knob

2

Pusher

3

Control lever assembly

4 5

Selector range lever Control lever bracket

6

Selector rod

of ft lb

@

T

07 to 0

@

T

16 to 2

T

3 to 4 22 to 29 0 35 to 0 45 5 to 3 3 2 0 8 to 1 6 to 8

@ C8i

T T

0 5 to 0 9

13 0

2 12 to 16

Fig AT 51

Control i kage f

tem sy

REMOVAL AND important

INSTALLATION

as

Inspection of oil level

Disconnect

control

control

knob

lever by removing

from

two

2

screws

2

Remove console box

3

Remove

selector

rod

selector

range lever and control lever assembly with bracket To

install

reverse

the

order of

removal

Therefore exercised

adjustment

trunnion

1

Prior to installing control knob A to II to 12 mm

set the dimension

Install control knob same

time

is

as

@

Figure

on

lever At

check the dimension

and adjust it to See

C

1 to 0

1 mm

by turning pusher

AT 51 AT 35

Set

and selector lever moreover

to I mm

in or

out

J

@ the

set

0 039 in by

adjusting

with connects

nuts

at

selector rod

@ After

adjusting

make

sure

that

be set in any position and that selector lever oper

control lever

0 43 to 0 47 in 2

@

@

nuts

adjust

position

clearance

turning

0 004 to 0 043 in

of linkage

faulty adjustment

N

at

transmission

B

The

should be

will result in the breakdown of the

the

ADJUSTMENT

great

because

care

Loosen

control lever

for the automatic transmission 1

3

can

correctly ates properly without

any

binding

If levers do not operate satisfactori

ly readjust sary

or

replace parts

as neces


MAJOR REPAIR OPERATION CONTENTS SERVICE NOTICE FOR

DISASSEMBLY

COMPONENT PARTS

AND ASSEMBLY

TORQUE CONVERTER INSPECTION

SERVICE NOTICE FOR DISASSEMBLY AND ASSEMBLY I

It

is advisable that repair opera tions be carried out in a dust proof to

the

differences

of the

engine capacities the specifications of component parts for each model s transmission may be different They however

have

adjust

common

and repair

ment

procedures as well as inspection procedures

and

cleaning

LOW

SERVO PISTON

42 AT

AT 36

GOVERNOR

43 AT

AT 38

OIL PUMP

AT 38

PLANETARY CARRIER

AT 44

CONTROL VALVE

AT44

3

During repair operations refer to Service Data and Specifications see

for the correct parts for each model tion

Before

semblies

removing any thoroughly clean the outside prevent dirt

from entering the mechanical parts 5 Do not use a waste rag Use

housing

2

sleeve bolt Withdraw pinion

Remove

bosses

and

affected Refer to the

of

extent

As

a

how they

are

Service Data

for

damage

rule

pilots

and

converter

due

to

2

diaphragm rod

follows

5 liter 0

I

pinion

Remove downshift solenoid and

phragm

as

Remove

speedometer

burnt clutch

into torque converter

mately

Remove

vacuum

Drain oil in torque converter Pour non lead gasoline or kero

sene

to transmission case

converter

oil is fouled or

flush the torque converter

I

3

4

completely

contaminated

torque

sembly

Do not leave dia

this stage of disas Rod is assembled in top of at

diaphragm

vacuum

See

Figure

AT 53

approxi

U S pt U

Imp

3

Blow air into torque converter

and flush and drain out

Fill

4

converter

torque

gasoline with

converter

torque oil

approximately

I

5 liter 0

V S pt U Imp pt blow air into torque con Again

5 verter

Fig

AT 53 Down hilt olenoid and

and drain torque converter oil

vacuum

dilJphragm

Remove bolts which hold valve

body


See

Figure

AT 54

wash all dis

that

justifies

replacement 7

from

rust

Remove bolts securing converter

5

assembled parts and examine them to see if there are any worn damaged or

parts

43 AT

Check torque convertf for any sign of damage bending oil leak or deformation If necessary replace

a

or

defective

42 AT

1

TRANSMISSION

paper cloth After disassembling

6

BRAKE

2

of subas

of the transmission to

nylon

REVERSE

pt

outlined hereinafter

4

41 AT

If torque

Due

do

REAR CLUTCH

INSPECTION

room

2

40 AT

AT 36

AT 36

DISASSEMBL Y

ASSEMBL Y

FRONT CLUTCH

AT 36

TRANSMISSION

INSPECTION

AT 40

AT 36

packings

seals

and

DISASSEMBLY I

Drain oil

extension

from

the end

Mount

of

rear

transmission

on

Transmission Case Stand ST07870000 ST07860000 Remove oil pan See Figure AT 52 or

similar parts once disassembled should be replaced with new ones

Fig 6

TORQUE CONVERTER The torque converter is construction sembled

and

can

not

a

be

stem

welded disas

AT118

Fig

AT 52

Removing

AT 36

oil pan

AT 54

Removing

Loosen lock nut

D

as

@

valve body

on

piston

shown in Figure AT 55

Then tighten piston stem in order to prevent front clutch drum from falling when oil pump is withdrawn


Ii

AT127

AT124

AT121

Fig AT 61 Remouin Fig A T 55 Loosenin

band seruo

Withdraw oil pump using Sliding Hammer ST25850000 Do not allow 8

front clutch to and

come

onto

drop

out of

floor

rear

extension

shell

With the aid of Snap Ring Re HT69860000 pry snap ring off

12

Pull out input shaft

7

Fig AT 58 R mouin connectin

16

Pull out output shaft remove oil CV together with governor

mover

distributor

output shaft See Figure AT 59

valve

CD

See Figure AT 62

position Figure

See

AT 56

Fig AT 62 Remouinggouernorand Fig AT 59 Remouing sruzp ring

oil distributor

connecting drum and

Pry off snap ring using a pair of pliers Remove retaining plate drive plate driven plate and dish plate in 63 AT that order See Figure

AT122

Fig AT 56 Removing oil pump

13

Remove

inner gear of rear an

Remove band strut This

9

done See

by loosening piston Figure AT 57

can

planetary

carrier as

assembly See Figure AT 60

be

17

stem further

AT126

Fig AT 63 Remouing driue and

Fig AT 60 Remouing connecting

driuen

drum

Fig

AT 57 R

moving

band strut 14

10

Remove rear

brake clutch

band as an

front

assembled

unit

connecting shell rear clutch hub and front planetary carrier as a unit See Figure AT 58 11

Remove

snap

rings and then

planetary

carrier internal

Remove

remove rear

clutch and

plates

connecting drum

one

way clutch

18

Reaching through back side of

transmission

case

slotted

bolts

outer race and one way clutch in that

AT 64

To

oroer

Extension

gear

15

Remove

rear

extension

loosening securing bolts 61 AT

See

by

Figure

ST25570000

do

hex head

remove

shown this

use

in

Figure

Hex head

ST25570001 One way clutch inner

washer

piston

race

thrust

spring

and thrUst spring ring

be removed AT 37

as

return

can now

Transmission

Automatic

i

I

Up

0

V

t

iL

lli

0

I1

ST25570001

J l

@

j

Lj Y

h 1

AT130

j

l i

rr

J

0

1

l

P

Ii

61

p

i

l

dng

Seal

ll

t

1

w

J1i

@

Clearance

j 1

j

ry

J

AT133

I

Fig AT 67 Removing manual plate

I

Fig AT 64 Removing hex head slotted bolt

22 19

Blowout low and

brake

reverse

piston by directing a jet of air into holeJn cylinder See Figure AT65

inhibitor

Remove

manual shaft by

switch

loosening

and

two secur

ing bolts

AT134

Me qsuringseal ring to

r 68 A

ig

ring groove clearance

ASSEMBLY

Assembly is in reverse order of disassembly However observe the fol lowing assembly notes After

INSPECTION Torque

rear

I

Fig AT 65 Removing piston

extension

Check for damage

necessary

20

Remove

band

attaching

bolts

Note

difficulty

If

loosening

servo

or

surfaces

mating

score

Repair

marks

as

way

clutch

inner

Torque

race

hex head slotted bolt to L3to 18 kg m 9 to 13 ft ib using Hex head Ex tension

Torque Socket

ST2SS7000 Wrench

ST2SS70000

GG93010000

and

ST2S490000

Extension

nee

See Figure AT 69

ST2SS 12001

essary

is encountered in

removing retainer direct a jet of air toward

on

cracking if

or

replace

Check for dents

2

one

and

case

of low and

assemble thrust spring reverse orake ring return spring thrust washer and

housing

converter

transmission

installing piston

release

side

shown in

as

3 or

If rear extension bushing is worn cracked replace it as an assembly of

bushing

and

housing

rear extension

ST2557000t

Figure AT 66

ST25490000 I

II

GG930JOOOO

Gaskets and O ring 1

Always

use new

gaskets

when the

units are to be disassembled

Check O rings for burrs or crack ing If necessary replace with new rings 2

AP

I

Fig AT fiB Removing bond servo

Check for signs of

rings

CD

from both

ends of parking brake lever @ and lever remove the Back off manual shaft

lock

plale @ Figure

nut

and 67 AT

ID

and

remove

parking

rod

manual

CID

See

wear on

seal

ring and ring groove replacing with new ones

snap

ont

if found

worn

beyond

use

Check that clearance between seal ring and ring groove is correct If out is of specification replace whichever worn

beyond

limits Correct clearance

is from 0 04 to

0 0063 in

16 0

See Figure AT J8

mm

68 AT

0 0016

to

woy

clutch

inner

2

011 distributor

Pry

Fig AT 69 Installing

fWl1 AT132

21

A T135

After low and

been assembled

reverse

measure

race

brake has

the clearance

between snap ring CD and retaining plate @ Select proper thickness of

retaining plate

plate

to

give

clearance See

correct

Figure

ring

AT 70

Low and reverse brake

clearance 0 80 to 1 05

rom

0 0315 to 0 0413 in

to


Install

planetary

rear

clutch hub and front

carrier

shown

as

in

Figure

AT 72

Rear

i c

clutch N edle bearing

Bearing Fig AT 70 Measuring ring

to

plate

AT139

A AT142

retaining plate

I

Fig AT 75 Measuring the distance

clearance

Available

race

Fig AT 72 Installing planetary carrier

2

the distance

Measure of oil

D

and

cover

pump

as

B

C

and

shown in

Figure AT 76 Thickness

mm

1l8

0 465

12 0

0472

12 2

0480

124

0488

12 6

0496

12 8

0 504

8

in

Assemble

connecting front

other

parts

reverse

order of disassembly

to

up

shell

and

Clutch

in

IL

Oiipi mp

I

AT140

Measuring the distance

Fig AT 76

B For

and

inspection procedure

reverse

brake

see

page

for

low

42 AT

for

Assembly 3

Install

vehicle

only

one

mark

arrow

It

way clutch so that the is toward front of

should be

free

in clockwise direction

to

rotate

AT143

Fig AT 73

Installing connecting shell

9

total end play and front

Adjust

end playas follows

B

W

r

L

thickness of oil pump

Required cover

L

bearing race

mm

Measured distance A

mm

in

B

Measured distance B

mm

in

W

Thickness of bearing

temporarily

race

inserted

mm

r

CD

Available oil pump

L

J

I

@

play

1

cover

bearing

race

Thickness

One way clutch

mm

2 1

047 0

I 4

0 055

in

AT138

installing rear extension torque attaching bolts to 2 0 to 2 5 Place manual kg m 14 to 18 ft lb 4

After

lever in P that

rear

2

range and check to be sure output shaft is securely

Front

clutch

5

Trammission

1 6

0 063

thrust

washer

6

Oil pump gasket Oil pump cover

1 8

0 071

bearing

2 0

0 079

2

0 087

3

Oil pump cover Front clutch

4

Rear clutch

blocked 5

Tighten at this

case

race

Fig AT 74 End play servo

retainer

temporari

stage of assembly 6 Place rear clutch assembly with needle bearing on front assembly ly

7

1 C

Measure the

by

Figure

vernier

distance

calipers

as

A

and

shown

in

Specified

total end 25100 0

play 50

mm

0 0098 to 0 0197 in

AT 75 AT 39

in

A

I

AT137

Fig AT 71

A

TT

Front end play

Total end

play

Select oil pump cover bearing race by calculating the following formula

TT

AT 71

o oml

of total end

Adjustment

D

where

See Figure

mITIJ

and

in


02

D

C

TF

H

check

be

to

properly in detailed procedure

mm

it

that

op

refer

ni i

For

range

page AT and Adjusting Inhibi

ing Checl

49 for

sure

each

erates

II

to

A

c

iif

tor Switch

where TF

i

n

stalled

t front dutch thrust washer by Sele calculating the following formula

i

in

is

switch

inhibitor

After

12

Adjustment of front end play

clutch thrust washer

mm

in

C

Measured distance C

mm

in

D

Measured distance D

mm

in

L

between

L

length

Check the

13

thickness of front

Required

1

throllle case end to rod end ofvacuum Then select in valve fully

AT145

pushed

of corre adequate diaphragm rod sponding measured length See Figure

Fig AT 77 Measuring the distance L

AT 77 Available

diaphragm

rod

Available front clutch thrust washer Thickness

Distanl e measured

L

Under25 55

OO59

in

mm

l

25 65 to 26 05

5 1

0 059

I 7

0 067

1 9

0 075

2 1

0 083

23

0 091

5 2

0 098

15 26

55 26

to

26 65 to 27 05

Over

27

parts

that

construction front end 0 5

to

1 0098 to 1 0256

29

10295 to 1 0453

30 0

1

10492 to 1 0650

30 5

1201

310

I

The transmission cons

106 0

play

sts of many

quite alike

are

machined

yet

close tolerances

to

in

very

When disassembling them in order in

parts be sure to place in part rack so they can be restored

0 8 mm

0 020 to 0 031 in

the unit in their proper

positions

It is

also very important to perform func tianal test whenever it is designated Notes Correct thickness of

a

bearing

race

and thrust washer is always the one which is nearest the calculated one

length

in

mm

29 00 142

1 0689

15 27

rod

Diaphragm

in

COMPONENT PARTS small

Specified

ITIm

FRONT CLUTCH

I

1161 5

off snap

Pry

suitable screwdriver Remove

a

plate CID

u

81

O

D

ring or

a

@

retaining plate

@

driven plate

with

a

pair of pliers drive

and dished

plate @ in the order listed in Figure AT 78

as

shown

I

Compress clutch Clutch Spring

springs using Compressor

2

ST25420001

or

Re

25420000 51

re snap ring @ from spring tainer using Snap Ring Remover ST2532000 I See Figure AT 79 move

Disassembly

b Installed thickness of oil pump gas ket is 0 4 mm 0 016 in Front clutch

10

Check

servo

piston

refer

ptocedure Servo

be

to

moves

Piston

that brake

sure

I

Pinon

freely For detailed

lcz

page AT42 for

to

Use

drum

to

care

AT147

prevent

piston from coming out of place dUI ing testing since servo retainer is not tightened at this point of assembly Make

II

sure

that brake band

Fig

correctly installcd

stem

to

Back off

f1 lb secure

12 to

with lock

ening torque is 9 f1 lb

Torque piston

5 kg 1 two nut

5 1

to

9 to 11

m

full lurns Lock 4 0

nut

kg

m

Removing snap ring

strut t

is

AT 79

and

tight

II

to

1

S

Snap ring

2 Retaining plate 3 Drive plate 4

6 Snap ring 7 Spring retainer

Driven plate

Fit

AT146

Dished plate

AT 78

8 Coil spring Sectional view of front clu tch

40 AT

Note sor

the

When Clutch

Spring Compres

ST25420000 is to be used toe

grinding

cut

tips of three legs by wheel See

Figure

80 AT

a

Automatic Transmission r

L

1

E 5 Eo

1

20

3

AT148

0

l mm

079 in

Cut off hatched portion

Fig AT SO Modifying coil spring compres

or

AT150

Lub ication hole

spring retainer f and See Figure AT 78 spring @ 4 Blowout piston by directing a jet 3

Take out

of air inlO hole in clutch drum

Figure

Fig AT B4 Testing front clutch Fig AT 82 Inserting clutch plate

See REAR CLUTCH

AT 8l

3

After clutch is assembled

make

that clearance between snap

sure

ring retaining plate @ is held within specified limits If necessary

CD

and

Disassembly

try with other plates having different thickness until correct clearance is obtained See Figure AT 83

Specified clearance I 6 to 1 8

0 063

AT149

Fig AT 81 Blowing

Available retaining

to

mm

0 071 in

plate

out piston

Thickness

mm

10 6

0417

Inspection

10 8

0425

I

11 0

0 433

112

0441

Check for signs of wear or dam to clutch drive plate facing If

age found

worn

discard See 2

damaged excessively

or

Service Data

Check for

for weakened

AT153

1 Rear clutch drum 2 Front clutch piston 3 Snap ring 4

for limits

on snap ring and broken coil spring

wear

or

in

II 4

0 449

116

0457

Retaining plate 5 Drive plate

rear

I

Take

@

plate

@

warpage

can

sembling Assembly of

snap

@ retaining @ driven plate f Same tech

ring

plate

be

applied

front

clu tch

clutch

as

in

See

disas

Figure

AT 85

Assembly

2

is in reverse the order

disassembly Dip

automatic

out

drive plate

and dished

nique

I

8 Spring retainer 9 Coil spring

Fig A T 85 Sectional view of

If necessary replace with new ones Spring retainer should also be in

spected for

6 Driven plate Dished plate

7

all

transmission

Remove

spring

parts in clean fluid before

snap

retainer See

ring from Figure AT 86

coil

AT151

installing 2

Line up driven plates so that stripped arcs are properly aligned paying particular attention to the loca tion of oil

holes in clutch drum

4

The number of drive and driven

plates varies with the type of vehi cle For detailed information see Service Data

Specifications

to

plate

clearance

See

Figure AT 82 Note

Fig AT 83 Measuring ring

Testing

front clutch

With front clutch assembled

on

ST2532001

oil

Xf

pump cover direct a jet of air into hole in clutch drum See Figure AT 84

Fig 41 AT

AT 86 Remolling snap ring


3

Blowout piston by directing a jet

of air

into hole in clutch drum

Figure

AT 87

w

1

See

Ai I

Without

setting

is within

j 3

i

above

between snap ring and retaining plate

1

i

the

disturbiilg

check to be sure that clearance

use

specified limits If necessary

other plates of different thickness

until correct

P2

is

clearance

obtained

0

i

V

Specified

clearance

0 80 to 1 05 rom

J

0 0315 to 0 0413 in i

AT157

j

4

Fig A T 89 Testing

rear

C U tch

Blow

in low

compressed reverse

air into oil hole

brake to test for

AT155

definite brake operation Figure AT 90 Fig AT 87 Blowing

ioW S REVERSE BRAKE

Refer to page AT41 for Inspection ofFront Clutch

Disassembly Fllow steps

1

as

described in page

AT 36 for Transmission

Assemble in

disassembly

After

parts

clean

in

fluid before

with type details refer to Serv

rear

sure

ring

held

clutch is assembled

D

that clearance be and retaining

within

plate toler

prescribed

Specified

AT 90 Testing low

reverse

brake

Inspection

plate facing for wear or damage if necessary replace Refer to Service Data Specifications for Check drive

I

spring for weakness Discard if weakened beyond Test

piston

return

use

clearance


3

1 0 to 15 rom

with

new

Disassembly I

Blowout piston by directing

of air into hole

a

jet

in release side of

piston 2

Remove

servo

piston

return

spring

ones

0 039 to 0059 in

SERVO PISTON

tolerances 2

See Figure AT 88

ances

Fig

plates varies

Specifications

tween snap is

the order of

mow out piston by directing a jet of air into oil hole in clutch piston

Note that the number of

check to be

l

all

Dip

of vehicle F or I

reverse

transmission

drive and driven ice Data

Disassembly

2

Assembly

assembling

shown in

out piston

Inspectl

automatic

as

Inspection Assembly I

piston is installed assemble thrust spring ring retum spring thrust washer and one way clutch inner race Using After

low

Extension

Hex head

ST25570000 ted bolt AT156

Fig AT SS Measuring ring

to

plate

clearance

reverse

Testing Install

rear clutch

rear

clutch

oil

ST25570001

3 to I

18

Insert dished

2

drive

Blow compressed air into oil hole shown in Figure

p

Note

to test for defInite clutch

89 AT

operation

as

v r

plate

plate

111

driven

and retaining

ring

to

secure

0

9 to 13

kg m

plate

plate

Ll

into

Install

the installation I

pump

cover

operation

ft lb

sn

on

proper brake

torque hex head slot

transmission case in that order

2

Check piston for wear damage or other faults which might interfere with

7 J

The number of drive and driven

plates

wries with type of vehicle

For detailed information Service

Data AT42

AT159

refer to

Specifications

Fig AT 91 Removing pi3ton


If primary governor is

assembled

for

any

purpose

spring seat primary spring and spring seat

be dis

to

remove

valve

governor

j i

r

11 @

I @

1

Anchor end

2

Band strut

3

Apply

4

Release

5

Return

6

Band

pin

Inspection

7

spring piston Band servo piston

8

Servo retainer

9 10

servo

stem

Brake band assembly Transmission

case

AT290

Fig AT 92 Sectional view ofseruo piston

faulty condition found weakened if spring Replace beyond use Faulty piston should also be replaced with a new one 2 Examine to see if primary gover nor slides freely without binding 3 To determine if secondary gaver I

Check valve for

nor

is

model

Assembly

in

blow air

good condition

under light pressure into hole at A and listen for noise like that of a

plane

Prior to assembly dip all parts in

I

clean automatic transmission fluid Reverse

to

i

assemble brake

aging rubber ring

care to

when

avoid dam

installing

seal

compressed

Blow

side

test

to

of piston

piston operation

definite

for

9c

Do not confuse

Note

with

primary gover secondary governor After

installation

fa

check that

spring

is not

from

pump

deflected

AT161

Fig AT 94 Testing piston

shown in Figure

as

Y

to

assemble governor

nor

t

apply

air from

1

disassembly procedure

Reverse

1S

z

1

i

lace 3

J

I

Use extreme

2

Assembly

o

7

procedure

disassembly

Release side

AT 93 GOVERNOR OIL

Disassembly

i8 ror1

1r c

7 f

J

0

2 nor

f

A 1

II

1 r

c

O

L

@ j IV I

iJ fl

n

0

Disassembly

tributor

I

1

Separate governor from oil dis by unscrewing attaching bolts To disassemble secondary gover

I

remove

spring

seat

spring and

secondary governor valve from valve body in that order as shown in Figure

PUMP

I

Free

pump

cover

bolts

housing by removing attaching 2

Take

out

inner and outer gears

from pump housing

AT 95 1

To control

val

5MI

AT160

Fig AT 93 Testing piston Apply side

n r

ID

3

Inspection

i

Inspect for wear or damage to Replace rubber ring if gear teeth found damaged beyond use 2 Using a straight edge and feelers I

Ii

measure

I

pump and gear clearances

as

follows Clearance between inner gear and pump

4

cover

or

See

outer

Figure

AT 96 4

apply

With

side of piston

with thumb blow

cylinder from Figure AT94 little it is bolts

are

an

compressed

release side

as

plugged

Line pre

sure

air into

shown in

If retainer is raised

a

indication that attaching

loose calling for

From control valve I

Standard clearance

ATOgO

I

I

Primary governor

4

Oil

2

Secondary

5

Output shaft

3

Governor valve body

governor

0 02 to 0 04 mm

distributor

0 0008100 0016 in

Replace if

Fig AT 95 Testing secondary

retightening

govemor 43 AT

in

over

0 08

mm

0

11 00


Replace if

over

0 80

0 0315

mm

in

6

CONTROL VALVE

u

The control valve assembly consists

ST255801JOO

of many preci ion parts and requir s extreme care when it has to be reo

AT264

moved and serviced It is good practice AT 96

Fig

Fig AT 99 Measuring

Measuring

runout

they 5

Clearance between

Tighten pump securing bolts specified torque 0 6 to 0 8 kg m

seal ring and

ring groove See Figure

Note

16 0

6

sembling Gauge

Seal ring

I

1n l AT

Fig

AT 97

5

Measuring clearance

Pump

As

is to be used make

Set up pump

housing

with inner

and outer pump gears on it 2 Using Oil Pump Assembling

carrier cannot

be

faulty

carrier as a unit

ST25580000

instail pump coverta pump housing as shown in

Gauge

Figure

clearance

between

washer and feeler See

if oil

should

be

di ssembled and

Remove oil

retain

moved

bolts

trainer

with

a

and nuts

recommended that and

HT62350000

be

Hexagon Spinner

Wrench

See

used

re

but it is

screwdriver

HT610oo800

which

Bolts may be

Handle

Figure

AT 101

Inspection Check

or

Disassembly

divided into its individual components If any part of component is

replace the

burnt

the control valve as

flushed

Assembly I

sembly

I

planetary

is

band

or

becomes fouled

PLANETARY CARRIER The

t

check to be certain that they are free of lint and other minute particles If

of oil

hole in side of it

a screw q

Oil

care

to

dip all parts in clean automatic transmission fluid and

clutch former

that

Before assembly

cover

When

so

positions Added

be exercised

scattered and lo

being

learance

Note

part rack

prevent springs and other small parts from

converter

runout

a

be reassembled in valve body

should also

4

bolt holes

check the

Again

pump

a1ign

to

sure

housing securing

mm

0 0016 to 0 0063 in

I

Be

parts in

can

in their proper

to

to 6 ft Ib

AT 97

Standarddearance 0 04 io

place

to

clearanc

planetary carrier Figure AT 100

pinion with a

Standard clearance

AT 98

0 20 to 0 70 mm 0 0079 to 0 0276 in

ST

5

000

I

J

Clearance HT61000800

I I

JL AT166

Fig

3

AT 98

Centering

Temporarily lighten

oil pump

pump

secur

ing bolts

Jr

Figure

11

2

r

bolts

Disassembling

plate for

valve body

bolts

attaching

removed

free

are

I

valve

lower

and upper valve removal

See

With

body

body Figure

AT 102 Note AT167

Fig

Remove

separate

4

Set the runout of oil pump cover within D7 mm 0 0 0028 in total indicator reading See AT 99

1

Fig AT 101

AT 100 Measuring pinion washer to

44 AT

ca

ier clearance

Do

not

allow orifice

vah e and valve

body

spring

check

in lower valve

to be scattered and lost when

removing separate plate

Automatic Transmission Note

I

Do not

w

it

off with

screw

drivers To avoid darnagingmachine

F

1

D

screws

do

not

work it

ff with

screwdriver

l t

a

f

J n Ull IU

P

19l1

C

J o

CJ CC

t lhl

fB

IODrR SJQIl2J

LL6

rt

Fig AT 103 Removing manual val

AT169

5

Fig AT 102 Removing separate pllJte

Remove side plate

pull

out pres

regulator valve second lock valve pressure regi1lator plug and two valve sure

springs 3

Pull out manual valve

Figure 4

shown in

as

6

Ar103

Remove 1st 2nd

Remove

plate side

shift

Take

plate

valve

With

plate

solenoid

side

downshift

valve

throttle back up valve vacuum 2 d 3rd t ing valve and three valve springs are free for

out

2nd 3rd

side

removed

shift

AT1

valve

pressure modifier valve and three valve springs See Figure AT 104

1

throttle valve HT61000800

Fig AT 104 Removing side plate

removal

g p

or

e eguJa Of le6Ve I @iO

f

reguJl

essure r

oL

g y

2I JI

h l

r

Io

t

SecOni J

lOCltvalYi

l J j

1

i 2nd

S

taltimivneg

3rd

r

0

r

x

en i C 1iJrilth rottle

t i

3

1

lY e

lI

a M

1

st

2nd

2i1d

S

ft

alVSY aIvel

I j1

f

If

2i

3

CP

g

dSt1itLvalv 3

fI iit a

so

hrottle f

iicnjp

P

ie

mo

stiift

i V81v

yi VB

i

Fig

AT 105

Components ports of control

uolue

Inspection r

I

Check valves for sign of

burning

and if necessary replace 2 Check to be certain

that

strainer is in good condition

If found

damaged 3

oil

in any manner disCard

Test valve

springs

for weakened

tension

5

4

if necessary replace Examine for any sign

Check oil

oLdamage

for sign of

marks on separate plate If left unheedcd oiL will bypass correct

tions which

oil

6

or

score

passages causing many types of abnormalities in thesystem AT45

er

passages in valve b dy

damage

and other condi

might interfere valve operation Check bolts for

Replace

as

required

with prop

stripped

threads

Automatic Transmission Valve spring chart

Valve spring

Installed

Mean coil

Wiredia

No of

dia

in mm

mm

free length

active coil

mm

in

Length

in

mm

Manual detent

6 0

3 1 0 051

Pressure regulator

Pressure modifier

2 1

5 10

2nd shift

4 0

3rd shifl

06

2nd

3rd timing

Throule back lIP

Solenoid downshift

07

6

Second lock

0 55

5 0

Orifice check

0 9

Secondary

Free A

f i n

n

0 740

22 0

12 5

12 0

lenglhm DO ri

Wire dia

AT172

sembly However observe the follow ing assembly noles Refer to Valve

Spring Chart and illustralion in as sembling valve springs Dip all parts in clean

Fig AT 106 Value spring

automatic

before assembly

transmission

Tighten AT46

parts

to

32 1

2

01 0

5 7

I

9

483

0 02 0 215

295 0

474 0

10 5

I 10

413 0

43 2

ifications when

Assemble in reverse order of disas

0 60

453 0

0 988

Assembly

installed

32 1

11 5

25 1

335 0

0 60

0 748

21 8

5 5

4 23

19 0

0 858

8 5

1 92

0 827

0 610 5 0

21 1

210

J5 5

327 0

0 55

0 492

1055

3 8

0 028

18 8

26 8

1878 0

0 0177

0 7 governor

14 0

4 77

45 0 governor

36 0

1417

33 5

0 220

3 09

1 063

319 1

5 6

0 0091

Primary

16 0

0 197

1 40

27 0

0 866

5 0

0035

0 23

12 0

0 197

378 1

0 669

5 32

14 0

0 625

17 0

1280

0 256

02

0 630

1 614

6 5

0 1

16 0

410

15 0

6 2

354 0

1 260

80

2 8

9 0

32 0

0 217

0 0217

Throule relief

6 0

5 5

0 0217

5 23

5 18

0 244

0 031

55 0

0

1 12

0 925

0 728

6 2

0 028

08

5 0

0 236

0 028

0 7

43 0

0 315

5

5

1043

1 693

80

0 024

2nd

13 0

kg lb

26 5

4 32 1276

413 0

0 047

0 016

1st

15 0

0 236

Load

in

designated

Slide valve into valve

particularly careful

that

body arid they

forced in any way 2 Install side plates Driver

fluid

Wrench

spec

AT l 07

are

be not

using Torque Hexagon HT6 I 000800 See Figure

ST25160000

and

Automatic Transmission Note

Install

spring so positioned

check valve and relief that they

are

properly

L

in valve body

ST25160000

Install upper and See Figure AT 108 4

J AT173

Fig AT 107 Installing side plate 3

Install orifice check valve

spring

valve

throttle relief valve spring and

steel ball in valve body

lower valves

HT6 1 000800 AT174

Fig AT 108 Installing valve body

Tightening torque 0 25

to

35 0

kg

m

5

2 to 3 ft lb

Reamer bolt tightening torque 5 0

to

0 7 kg

4 to 5 ft lb

AT47

m

Install oil strainer

Tightening torque 25 0

to

35 kg 0

2 to 3 ft Ib

m


TROUBLE

DIAGNOSIS AND ADJUSTMENT CONTENTS

INSPECTION AND ADJUSTMENT BEFORE

ROAD TEST

DIAGNOSIS

TRQUBLE

TESTING INSTRUMENT FOR

INSPECTION

CHECKING OIL LEVEL

CHECKING SPEED CHANGING

4B AT

CONDITION

AT49

ENGINE

IDLING

REVOLUTION

CHECKING

DqWNSHIFT SOLENOID Qt CII 8li p JYSTMs T OF L

N JJ

AT 52

SHIFT SCHEDULE

AT 52

PRESSURE TEST

LINE

KICKDOWN

SWITCH AND

AT 52

PRESSURE governor feed pressure

JUDGEMENT

49 AT

IN

3

AT

TR6 uBLE SHOOTINC CHART

49 At

CHECKING AND ADJUSTING INHIBITOR

INSPECTING

SWITCH

AT49

TROUBLE

STALL TEST

AT 53

ITEMS

AT 53

SHOOTING CHART FOR 3N71B

AT 50

AUTOMATIC TRANSMISSION

STALL TEST PROCEDURES

AT 50

TROUBLE

JUDGEMENT

AT 50

AUTOMATIC TRANSMISSION

Since most automatic transmission troubles

be

can

adjustment

do not

Firstly inspect

adjust the auto matic transmission in place utilizing the Trouble Shooting Chart If the trouble can not be solved by procedure

and

remove

and

disas

semble the automatic transmission is

check

advisable to

repair each part

overhaul

It

Trouble

Shooting

I

In the

Trouble

Chart

items The transmission should not be

on

meas s

should be

and the data should be recorded

INSPECTION AND

ADJUSTMENT DIAGNOSIS

I

Engine

Vacuum gauge

tachometer

Approxi

of operation will

raise the temperature to this range idling conditions are stabi Then the

CHECKING

OIL LEVEL

tion the car must be

checking

the automatic transmis

trouble shooting oil

in

linked with

an

easy and effective since some

procedure condition

are

shift

and lever

on a

level

The amount of the oil varies with the temperature As a rule the oil level must be measured after its temper ture becomes

often 1

developed troubles

placed

surface

sion the oillevel and the condition of

changes

the brakes

apply

transmission

through all drive positions and place it in park P position In this inspec

sufficiently high

Fill the oil

the line

to

H

The

difference of capacities between both For instance

by

causes

faulty operation

making the clutches

slip resulting

in severe

and

brakes

This is because the oil pump sucks air causing oil foaming thus rapidly

deteriorating ducing sludge

H

and

L

is

liter

Ji

VS

p

therefore line

wear

the oil quality and pro and varnish

approximately 0 4 Y Imp pl and

do not

fill beyond the

to

H

2

When

oil

care

topping

up

and

should be taken

mixing the oil with dust and

changing

to

prevent

water

Excessive oil is also bad because of oil

foaming

up the oil

caused by the gears stirring

During high speed driving

excessive oil in the transmission often out from

the breather

InspectIng 011 condition The condition of oil

sticking

to the

level gauge indicates whether to over haul and repair the transmission or look for the faulty part

TESTING INSTRUMENT FOR

2

l760F

122 to

SO

temperature

o

ten minute

mately

lized

blows

INSPECTION

800C

to

move

In

AT 57

and engine

Lack of oil

the basis of standard values

BEFORE TROUBLE

these

seat

removed unless necessary

adjustments

install

way that allows

examined This is

Shooting

diagnosis items are arranged ac cording to difficulty from easy to difficult therefore please follow these

Tests and

a

to

oil around the oil level gauge should be

Chart

the

made

convenient

FOR 3N71B

ing temperatures

urements to be made from the driver

and

in the order listed in

the

2

is

instruments in

mediately

this

It

disassemble im

AT 54

SHOOTING GUIDE

3 Oil pressure gauge

repaired by simple

AT 53

MEASURING LINE

PRESSURE

LINKAGE

MANUAL

AT 52

CHANGE

LINE

49 AT

AND ADJUSTING

AT 51

CHECKING ITEMS DURING SPEED

EAKAGE

CHECKING

SHIFT

48 AT

INSPECTION AND REPAIR OF OIL

AT 51

VEHICLE SPEED AT GEAR

AT 4B

If the

Measuring

011 level

To check the fluid level

engine

and

run

start

the

it until normal operat AO T

oil

varnish ike

has

quality

trol valve to stick cates a burned

deteriorated to

a

it causes the con

Blackened oil indi

clutch

brake band etc

Automatic rransmission In these cases

and deiecl the spol of oil eakage l se nonflammable organic solve t s ch as

be repaired Notes a

In

checking

oil

cloth

to

paper

level

use

handle

special

the

level

gauge and be careful not to let the scraps of paper and cloth stick to the gauge b

Wipe off the leaking oil and dust

the transmission must

Insert the gauge fully and take it quickly before splashing oil

out

tcmperalure by op the erating engine and shift the lever Raise

automatic transmission

Use

DEXRON

having

increase

to

the oil

pressure The spot of oil lcakage will then be found more easily

er

at

LINKAGE The adjustmcnt of manual linkage equaUy important as Inspection of

is

for the automatic transmis

Oil Level

Thereforc

great care should be exercised because incorrect adjustment sion

will

in the brcakdown of the

rcsult

transmission

sible

to

place except when high speed it is impos

locate this leakage with

Inspection

vehicle stationary

the selector lever toward you

Pull

trans

and turn it

mission

as

far

P

as

to

I

range

wherc clicks will be felt by the hand

d Pay attention because the oil to be used differs from that used in the Nissan

OF MANUAL

does not take

running

fluid

leakage from the breaih

As oil

Note

identifications

only in the 3N71B automatic

D

to

the oil

AND

ADJUSTMENT

carbon tetrachloride for wiping

adheres to the gauge Then observe the level c

INSPECTION

Full

Automatic

TranSJTIis

sion 3N71A Never mix the oils

CHECKING ENGINE IDLING

This is the detcnt of manual valve in

REVOLUTION

the

revolution should

engine idling properly adjusted If the engine revolution is too low the engine does not operate smoothly and if too high a strong shock or creep develops when changing over The

OF OIL LEAKAGE

from

leakage takes place the portion near the leakage is covered with oil presenting difficulty in

N

to

D

indicates th

and

body

position of the lever Inspect whether the pointer

be

INSPECTION AND REPAIR

valve

correct

of

selector dial corresponds to this point and also whether the lever

in

comes

alignment with the

stepping of posi tion plate when it is released

R

or

When oil

detecting

the

spot

Therefore

places where oil seals and gaskets equipped are enumerated below 11

the

CHECKING AND ADJUSTING

are

KICK DOWN SWITCH AND

This

ed

refcrring

can

to

be

accomplish

page

AT 35 for

Removal and Installa tion

Converter housing

Oil seal of engine crankshaft Bolts of converter housing to Trarismission and Junction of transm

extension

rear ss

case

extension

ion and rear

Figure AT il2 Mounting portion of vacuum phragm and downshift solenoid Breather and oil charging pipe Speedometer pinion sleeve to

se

the kickdown operation is

made properly or the speed chang ing point s too high check the kick down switch

downshift solenoid

wiring between them When li n key is pqsitioned a t the deeply

Oil pan Oil pressure inspection holes Refer

Oil

When not

nd the accelerator

J

Oil cooler tube connectors

dia

pedal

is

the

igni

I st stage

depressed

closed and the solenoid should click If

indicates

it

a

INHIBITOR SWITCH

and

the switch contact should be

it does not click

CHECKING AND ADJUSTING

The inhibitor switch lights the verse

the starter and

Then check each part with the testing instruments See Figure ATl09

d

leaka le

as

@

I

7 @

sampling

t a

pit and by AT10S

the leaked oil determine if it

the

torque converter oil The torque converter oil has a color like r d wine

So

it is

oil

or

easily distinguished

gear oil

from engine

Fig

AT 109 Downshift solenoid

Watch

oil

for

transmission case 4Q AT

leakage

from

motor

in the ranges

ol peratio and also rotates N

b ell L

@

If t

dl

@

4l

1l j7 @

AT109

t

Inhibitor switch

6

Washer

2

Manual shaft

7

Nut

3

Washer

8

Inhibitor switch

4

Nut

9

Range select lever

5

Note

range

CD

follows

Place the vehicle in

re

of the

P

defect

l of rear extension

proceed

lamp

R

in the

transmission

To exactly locate the place of oil

is

by

procedure

DOWNSHIFT SOLENOID

Rubber ring of oil pump housing Oil seal of oil pump housing

2

Adjustment

Manual plate

Fig AT 110 Construction of inhibitor switch

Automatic Transmission Chcck and the

whether the

starter

in these

ly

lrouble

vehicle is held in

lamp

reverse

operate normal

motor

The carburctor is in full throttle opera tion with the selector lever in ranges

If Ihere is any

ranges

first check the

If

linkage

2

f

no

and

the

I

fault is found in the linkage check the

pare

inhibitor switch

slandard values

Separate

selector rod and turn

the range selcct lever In the

N

position

the tester

Using

BY

yellow

I

the slot of

the

check

in the range

2

Torque tioning

3

Engine

two

for continuity Turn lever in both directions

the

select

electricity is on while the lever is an angle of about 30 on both

within

sides from each lever set if its

line

How

range is obvious

continl ity ly unequal on both sides adjustment required ever

If any the

screw

malfunction is

fastening

of the switch

body screw

found

is

fastening

and then

bolts

remove

under the switch

becomes

vertical

the

works to position the shaft with

detent

correctly

clicking sound MSlVe the switch slightly a

that the

screw

asjJe

so

hole will be aligned

with the pin hole of the internal rotor combined with the manual shaft and check their alignment by inserting a 5 mm 0059 in diameter pin into 1 the holes

If the alignment is correct

as

pin tighten up the

screw

and fasten the selector

before Check the continuity

again with the tester If the malfunc tion still remains replace the inhibitor switch

The purpose of this test is to check

the

For

properly

normal

rpm

the selector lever in the range P for several minutes Warm up the torque

clutch

slipping

converter oil

clutch

High

fro

the dri

specified

on

2

seat

er s

at

visibility and put a mark

revolutions

on

Secure the front and

To

wheels

apply the hand brake depress the brake pedal

a

foot before de

Throw the selector lever into

the

range 1 4 Slowly

If

whilc

engine

revolution

begins

to

rotate

when

at

approxi

rpm minute to cool down the torque verter oil and coolant 6

2

one

con

Make similar stall tests in ranges I and RIO

The stall test operation

as

speci

item 4 should be I l3de fd in wiihin five seconds If it takes too

long

the oil

deteriorates

brake and band

an

the

ad

the transmission and engine for trou

clutches

ble by measuring the maximum num bers of revolutions of the engine while

versely affected Sufficient cooling

are

time should be given between each AT 5O

brake

slipping

1

the lever

However if it 2

in

revolution increases

to

as

in

properly the is slipping clutch is slipping

of the band brake is diffi

cult to ascertain

level

starting engine

brake

the front

Slipping

range

work

not

Jp

I strange

occurs

engine

range

to thesarne

It is

impossible

check it in the stall test

Standard stall revolution

2

If the engine N

for more than

200 1

is

after

coasting

reverse

Otherwise

pedal

the engine

reverse

engine

and then

the selector lever to

operate

mately

the

steadily

release the accelerator Shift

and

with

depress the accelerator until the pedal throttle valvc is fully opened Quickly read and record the

Front

only

which

with the lever in

pressing the accelerator pedal 3

and

2

One way

road test is nceded

low

with the left

R

determine

braking does

fumly

and I

low and

or

Be

to

0 in

in

rpm

with chocks and sure

and

Rear clutch

front clutch or low and reverse brake

the meter

rear

I

and

slipping

a

good

2 R

in

rpm

High

suitable temperature 140 to 2l20F

allows

D

rpm in

slipping

to

that

test

low Iine

in all ranges

High

Mount the engine tachometer

are

further

presumed

causes are

engine cooling water to suitable tem perature by running at 1 200 rpm with

I

no

following abnormalities

normal rpm in

Note

STALL TEST

therefore

required

is

for overall

and

Before Icsting c heck the engine oil and torque converter oil warm up the

and

lever

slipping

pressure

pull

the hole

for proper fune

STALL TEST PROCEDURES

fasten the switch body with the bolts in

slipping

converter

or more

transmission

the

High rpm

location

in stall

indicates that one in

clutches

the respective

5

out the

than

more

engine revolution

it

values

un

body Adjust the manual shaft correct ly to the position N by means of the selector lever When the slot of the shaft

brake and band in trans

6010 1000C

nut of the range

selector lever and two

the machine

If the

R

from each lever set position and check each continuity range It is normal if

revolution

stall

condition is higher than the standard

mission for

wires from the in

be tested and

items

Clutches

hibitor switch in the ranges N and I and the twre d black RBj wir s range

JUDGEMENT

High

Components to test

N

to

2

standard revolution

the manual shaft is vertical

black

results with the

the manual lever from Ihe

remote control

Note

respectively Com

measured

0

test for the four ranges R I and

stalled condition

a

condition values

is

I

and

Also

tIle

clutch

the

the control elements

mally operating 2

revolution

within

of the

normal in

in the

in stall

standard are

ranges

nor

0

R

engine torque

and

one way

converter

are

and operation The one way clutch of the torque converter however sometimes sticks

performance

This is determined in the road test 3 Lower stall revolution than stand ard revolution If the

engine

revolution in stall

condition is lower than the standard

Automatic Transmission torque converter s one way clutch sticks vehicle speed can not exceed approximately 80 km h 2

values it indicates that the engine is in abnormal condition

or

the torque con

verter s one way clutch is

slipping

Others

is poor until vehicle mately 50 km h 30 MPH

and then normal can

be

judged

that

beyond

speed

verter s one way clutch is

care

guide speeds

is

If the

it

con

down

diagnosis

for each stage of the up and shiftings be prepared Measured

vehicle speeds

are

to be filled in the

adjoining column after each testing

slipping

Also

it

is

advisable to mount

Kickdown

0

Half throttle

Fuol throttle

200

51 to 65

D2

92 to 106

D3 D2

D3 D2 Dl

Dl

D2

9t023

D2 D3 D3 D2

D3

48 to 61

Note

D2 Dl Dl

12

I

12

I

can

2x

1f

x

rx

RF

x

where

3 340 to 3 840

82 60 to 51

3 460 to 2 960

6toI4

19

I

x

51 to 38 32 to 24

1 860 to 1 360

51 to 38

1 860 to 1 360

range from

D

following

32 to 24

range

output shaft 2 000 rpm

formula

60

h km

Propeller

R r

Final gear ratio Tire effective radius

TT

The ratio of circumference of a circle to its diameter

revolution

rpm

m

375 4 6 00 14

AT 51

850

700 Max

Np

0321

1 350 to

1 000

shaft

830

1 720 to 2 220

12

Vehicle speed

RF

330to

30 to 38

V

r

1 790 to 1 290

30 to 22

37 to 24 23 to 15

1

Np

1 840 to 2 340

or

be calculated by the

V

to

Propeller shaft rpm

MPH

57 to 66

49 to 36

1

speed by shifting to

Vehicle speed

96

km h

32 to 40

D2

450

Reduce the

speed

Dl

0

Minimum throttle

Vehicle

Gear shift

mmHg

14 3

a

the throttle

SPEED AT GEAR SHIFT

Throttle opening

an

chart with the standard vehicle

stopper for positioning opening

VEHICLE

the auto

diagnosis

It is recommended that a

so

required 3 transmission does not op erate properly at all vehicle speeds it indicates poor engine performance special

is attained

that the torque

exact

knowledge of

transmission is required for

ltic l JT

tem

and

abnormally

rises

perature

performance speed of approxi

If the accelerating

1

oil

torque converter

the

case

An accurate

in the road test In such a

50 MPH 4

ROAD TEST

If the

Automatic Transmission SHI

CHECKING SPEED

SCHEDULE

CHANGING CONDITION The

driver

s

feeling during

hk

gear

changes should also be checkedatten tively

12

100

2

I

1

I 2

I

sharp shock or unSffioothness is felt during a gear change A gear change is made with a long 2 I

A

These

indicate

oo

I E

I I 300

I

Z 5

that

the

I I

3

c

dragging feeling

and

J

I

2

3

L1

mmHg

tIuottle

t

400

I

pressure is too low or some valve connected to the throttle is faulty

I

3SA

1 500

000 Output shaft speed rpm

CHECKING ITEMS DURING

I

In

D

D2

MPH

range

gear

D3

are

I

I

In

I

the

speed

io

io

60

50

70

R

4

315

Should be

quickly

fixed at

2

P

vehicle

can

321 0

r

he

parked

If any malfunction occurs in second is if gear during the road test that while vehicle shakes drags or slings

D

in

to

shifting

If these troubles remain after

adjusted check piston seal for oil leakage

the brake band is servo

directly

to up from D the brake band should be ad

or

D2 justed

D

the

ATll0

Shift IChedule

or

When

any

slipping

brake

or

the feeling

change is

not correct

occurs

in clutch

during

a

speed

the line pressure t I

Measuring line pressure

is done

by a

pressure gauge attached to two pres sure measuring holes after removing

1

I

l

1 D

c

properly

from

6 00 14

LINE PRESSURE TEST

case

plugs See Figure

located

at

transmission

7

jf

AT 112

line pressure measurement is at begun idling and taken step by step by enlarging the throttle opening

sharp shock in up shifting or too high changing speeds are caused mostly by too high throttle pressure 2 Slipping or incapability of opera I

c

o

The

shifting up

60

0

Fig AT 111

blind

range In 6

00 90100

80

40

30

Vehicle speed

does not in

crease

5

30 40

must be checked

erly 4

Ii

20

R

By moving the lever from D to 1 gear changes D 12 2 and effected In the ranges 12 the engine braking works prop

are

1O

changes DI

effected In

increase range the speed does not 2 The kickdown operates properly 3

hO

km

SPEED CHANGE

CV

ATl13

A

tion is

leakage

mostly

due to

oil

within the gear trains

valve

AT S2

pressure or

spool

1

2

Lige pressure Governor feed

3

SerVo release pressure

Fig AT 112

uring line preuure MeCJ

Automatic Transmission GOVERNOR FEED PRESSURE

LINE PRESSURE

At cut back

Range

15

Unit

After cut back

point

under approximately

Throttle opening

Unit

mmHg

Full throtlle

0

9 4 to 110

Minill1um throttle

450

3 0 to

Fulllhrotlle

0

Minimum throttle

450

Full throtlle

0

Minimum throttle

450

over

approximately 22 MPH

35 kmfh

kmfh 10 MPH

kgfcm2 psi

Unit

kgfcm2 psi 134 to 156

5 to

5 6

78

to

92

to

4 0

43

to

57

5 5 to

7 0

78 to 100

5 5 to

70

78 to 100

D 4 0

10 0 to 12 0

2

142

6 0 to 12 0

to

3 0

57

43to

171

85to171

14 0 to 16 0

199

to

228

43 to

78

14 0 to 16 0

199 to 228

R

3 0 to

2

I

R

and

pH

the pressure supply system output of power caused by

too low

or

of the

puncture

phragm

be

can

the

absorbed

checked

by

torque the

into

ascertained oil is

converter

engine

and

the

Low

idling

line pressure in

tain ranges only This is presumably caused

leak in the devices

by

cer

an

oil

nected to the relevant ranges When there is

I rear

clutch

the line and governor D 2 and I are low

pressure in but the pressure is norrrial in When

low and

an

reverse

pressure in

R

oil leak

in the

brake circuit the line

P

and

are

D

2 and

High idling line pressure This is presumably caused by

increased

owing

vacuum

or

by

an

450 mmHg and 0 with the stall test I

mmHg in accordance procedure

line pressure do not n despite the vacuum decrease

If

lo

78

check

whether

the

vacuum

rod

is

incorporated 2

pressure

increased

line

If the line pressure do not it is caused mostly

and piping

solenoid

kickdown

switch and wiring F

Engine idling rpm pressure throttle

G Oil

H Engine stall rpm I Rear lubrication Control valve manual

K Governor valve L Band

servo

M Transmission air check N Oil quantity o Ignition switch and starter motor P

Engine adjustment and brake spection

2

Inspection after inspecting

in

auto

meet

by

m

Rear clutch

n

Front clutch

a

TROUBLE SHOOTING CHART INSPECTING ITEMS Inspection with on

diaphragm

E Downshift

q Band brake Low and reverse brake r

u

Oil pump Leakage of oil passage One way clutch of troque coilVerter

v

One way clutch of transmission

w

Front clutch check ball

x

Parking linkage Planetary gear

s

mission

select linkage

matic transmission on vehicle

sticking pressure regulating valve pres sure regulating valve plug or amplifier

1

lge Ra

Inhibitor switch and wiring

D Vacuum

the

an

to a leak in the vacuum tube or

dia phragm

line pressure is increasing In this check the line pressure should be measured with vacuums of

low but

I

throttle

be checked when the

the standard

R

occurs

the pressure is normal in

Items to

crease

oil leak in the

an

4

circuits con

or

C

J

An

2

4

A Oil level

dia

vacuum

easily

exhaust pipe emits white smoke

oil pressure leak in the oil valve body or case pump A sticking regulator valve 3

3

A

because

A worn oil pump

2

2

leakage

is

directly measuring the negative pres sure after removing the vacuum pipe

be atlributed to trouble in

can

sticking regulator

a

B

Vacuum

Low idling line pressure in the D

due to

pressure valve

LINE PRESSURE

I

5 5

a

JUDGEMENT IN MEASURING

This

3 0 to

The line pressure during idling corresponds to the oil pressure before cut down at minimum throttle b The oil pressure After cut back means that after the pressure modifier valve has operated

Notes

ranges

5 5

automatic

vehicle AT 53

trans

t

y


TROUBLE SHOOTING CHART FOR 3N718 AUTOMATIC

TRANSMISSION

be taken up The number shown beluw indicates the sequence in which the checks should

Trouble

ngine does

EFGHIIJKL

ABeD

P

N

not start in

2

3

1

2

MNOP

stuv

tnnqr

wxy

1

ranges

Engine starts in other range than N and

P in

Sharp shock 0

shifting

to

2

1

@

3

4

I

2

3

1

2

4

5

6 3

1

2

3

5

6 4

1

2

3

5

6 4

1@

1

2

3

5

7

@@

range

Vehicle will 2u TUns in

not run

ranges

Clutch

bul

runs

R

Iukh

2

range

I

r

nges

run

brakes

runs

Maximum

@

@

@@ 1

@

in

in any range

slip

N

speed

@

poor acceleration

somewhat

6

starting

Vehicle

7

range bul

R

in

and

2

Vehicle will not

or

1

0

R

nol run

slips Very

Clutches

ranges

Very poor acceleration

slips

Vehicle will 0 runs in

in

range bul

D

in

and

l

Vehicle will not run in

in

N

from

allained

1

4

2

5

4

2

3

I

range

not

I

@

7

6

3

3

2 1

8

OO

I@

Acceleration poor Vehicle braked by Ihrowing Icver inlo R

No creep Failure

@

1

I

all

dumge

gear from

2nd

tllchJllgC

gear from

11

2

4

5

3

I

2

3

5

6

8

7

4

1

2

3

5

6

8

7

4

1

2

@@ @

1 @ @

3rd

Failure to

al

10

I I

Excessive creep

to

@

range

2ud

Too high I sC

to

gear change poinl from from 2nd to 2nd

@

@

a

3

5 6

1

4

3rd Gear rd

change directly

from

lsl

to

2

occurs

AT 54

4

3 1

@

@

@


Trouble

Too

sharp

l1st

to

EFGH

1

2

shock in change from

a

I J KL

MNOP

5

4

mnqr

s

t

u

v

w

x

@

3

2nd

Too sharp 2nd

ABCD

shock in

a

change

from

1

2

3

3

5

4

@

3rd

to

Almost

no

slipping

in

shock

change

no

shock

or

clutches 1st

from

to

1

2

3

4

6

8

7

1

2

3

4

6

8

7 5

@

@

5

2nd Almost

change

from

Engine

races

slipping

by

gear change from

Vehicle braked by gear 2nd to 3rd

3rd

to

Gear

from

change

gear from

change from

or

change

3rd

to

2nd

3

2

1

1

3 4

6

5 2

1@

I

3

4 6

5 2

1

@

high

a

from

1

2

3

4

5 6

f

I

2

3

4

5 6

f

2

1

from

change point

2nd

to

@

shock felt

during releasing accelerator pedal

3rd

@

V

lIst

deceleration by

Too

@

2nd

10

1st

to

1

2

gear from

change

to

Failure

@

@

2nd

to

Failure

in

3rd

to

extremely

Vehicle braked 1st

or

2nd

2nd

to

1st Kickdown does not operate when depressing pedal in 3rd within kickdown vehicle

or

when depressing

3rd

engine

pedal

beyond kickdown

speed

limit

Races

extremely

from

Jrd

to

5

3

5 6

7 4

@

f

speed

Kickdown operates runs

4

slips

or

2nd

over

in 1

vehicle

in

2

3

@

@

I

changing 1

2

4

I

2

4

I

2

3

when

6

5 3

f@

@

3

@

j

depressing pedal Failure to

to

when

change from 3rd changing lever into 2

range

Gear change from or

from

2nd

to

2nd 3rd

10

in

nd

1st 2

range

55 AT

51

@

y


ABeD

Trouble

No shock at or

range

change

engine

from

races

I

3rd

when shifting lever into

Engine 1

not

I

J K L

1M

NO

I

2nd

to

2

3

4

I

6

1m

n

change

from

frum

2nd

to

I sr

3rd

lu

in

q

I

2

1

I

2

4

57

7

5

@

6

3

@@

range

upcrate

P

r

t

s

u

v

Iw

x

y

I

@

@

in

@

5 3

range

Gear or

brake does

I

F G H

2

to

extremely

Failure to change from

E

f

2nd I

1

2

2

4567 3

@

range Does not to

1st

shock

Large to

change in

1st

Vehicle

changing

P

range

1

from

@

when

1

2

@

3

4

changing

range or parking gear does not disengage when shifted out of

Transmissic m overheats

Oil shoots out

2

2nd

range

moves

P

2nd

range

in

into

from

2

I

I

3 4

2 6

5 6

2 7

8

@@@ Q@@

@

8 4

@@@ Q@@

@

2

OG@@ f@@

@

7

5

during operation

White smoke emitted from exhaust

I

3

pipe during operation Offensive smell at oil

Transmission noise in

charging pipe p and

1

N

1

2

I

2

10

ranges

Transmission noise in and

R

D

2

I

ranges

AT 56

0

G

I @

@

Automatic Transmission TROUBLE SHOOTING GUIDE FOR 3N71B AUTOMATIC TRANSMISSION

Procedure

Test item

Order

Check gauge for oil level and leakage before and after each

Oil level gauge

Checking

test

2

Downshift solenoid

Check for sound of operating solenoid when depressing accelerator pedal fully with ignition key ON

3

Manuallinkage

Check by

L

shifting

into

P

lR

D

IN

and

2

I

ranges with selector lever 4

Inhibitor switch

Check whether and whether

Check whelher

5

Engine idling

6

Vacuum pressure of

rpm vacuum

7

Operation

idling

Creep

I

tesling

ranges

only

only

vacuum pressure is more than 450 mmHg it decreases with increasing rpm and whether idling

Check whether

of vehicle

Oil pressure before

p

range

Check whether transmission engages positively by shifting N l R range N I and N N 0 2

in each range

R

Stall test

R

rpm meet standard

while idling with brake 8

and

N in

Check whether in

pipe

operates in lamp operates

starter

reverse

applied

there is any creep

in

D

I

and

2

and

ranges

1

Measure line pressures in

2

D

R

range while

idling 2

Stall test

Measure engine rpm and line pressure in R ranges during full throttle operati n

D

I

2

and

Notes of torque converter oil used in test should be from 600 to 1000C 1400 to 2120F i e sufficiently

Temperature

a

warmed up but not overheated b To cool oil between each stall test for and

idle

R

engine

D

2

I

ie

rpm at about 1 200 P range Measurement

ranges rpm for more than 1 minute in time must not be more than 5 seconds 3

Road test

Same

Slow acceleration

Check vehide

I

2nd range and

st

2nd

2nd3rd 2

item I

Oil pressure after testing

Quick acceleration lst 2nd

D

as

and

speeds

range and engine

engine

cpm in

range while

Jo3rd 2nd

vacuum

shifting

up

running with

Ist

lever in

200 I11I1lHg pressure of about

except with engine vacuum pressure in position just before kickdown

Same as item 1 above

of 0 mmHg ie

2nd3rd 3

Kick down operation 2nd1st 3rd 2nd or

Check whether the kickdown operates and measure the time delays while running at 30 40 50 60 70 km h 18 25 30 37 43 MPH in

AT 57

D3

range


Procedure

Test item

Order 4

Check vehicle

Shift down

Dr

0

O2

speeds

2nd

3rd

accelerater

and engine rpm in shifting down from sequentially while coasting with

I st

pedal

released in

range and

D3

engine

vacuum

pressure of about 450 mmHg 5

Shift down

Check for

DJ 12

further for

1

shifting down OJ shifting down 12

and engine braking and

12 I

and

engine braking

after

I range with the accelerator pedal shifting released and the engine vacuum pressure of 0 mmHg while driving at about 50 km h 30 MPH in OJ range the lever into

6

Shift down

DJ 2

Check for

2 and engine

after

while driving

50

quick shifting down 0 shifting the lever into 2 range km h 30 MPH in OJ range check for locking of the regardless of vehicle speed

Further ratio 7 Shift up I

12

8 Shift up iog in 2 9

or

down when start

range

Parking

Abnormal shock oil leakage

about

at

transmission in 2nd gear

Check for failure of the transmission to shift up acceleration when starting in I range

during

Check the transmission for not

during

acceleration

or

P

shifting

move

on

as

rang

when

shifting

during

these tests

gear noise abnormal clutch noise and acceleration

performance

58 AT

grade

2

range

Enter into record conditions observed such

up or down

deceleration when starting in

Confirm that vehicle will not to

Others

biaking



General specifications AfT

Torque converter Type

Symmetrica13 element I 2 phase torque converter

Stall torque ratio

20

stage

I

Transmission

Type

3

speed forward and one speed

reverse

Control elements

Multiple

disc clutch

Selector positions

gear train

I

disc brake

I

One way clutch Gear ratio

planetary

2

Band brake

Multiple

with

I

1st

2 458

2nd

1458

3rd

1 000

Reverse

2 182

P Park

Transmission is placed in neutral shaft is fIXed

Output Engine

can

be started

R Reverse

Backward

N Neutral

Transmission is in neutral

o Drive

Engine can be started Up or downshifts automatically

running

to

and from I st 2nd and top 2 2nd lock

Fixed at 2nd

I

Fixed at low

Lock up

or

downshifts from

2nd Oil pump

Internally intermeshing involute

Type

gear pump Number of pump Automatic transmission fluid

Oil

DEXRON

type

5 5 liters

Capacity

4Ulmp qt Approximately 2 7 liters s qt SUU

s qt 2XIrnp qt 2UU in torque converter

Hydraulic control system

Controlled

by measuring the nega

tive pressure of intake manifold

and the revolution of output shaft Lubrication system

Forced lubrication by

Cooling system

Water cooled by

a

an

circulation type

auxiliary cooler located radiator

AT59

oil pump

at

the

Automatic Transmission Specifications and adjustment AfT


assembly

Model code number

Torque

converter

X2402

assembly

Stamped mark

on

th e

TiC

16 B

Front clutch

Number of drive plate Number of driven

3

plates

3

Clearance

mOl

in

16 to 18 0 063 to 0 071

Thickness of retainin g plate

mm

in

10 6 0 417 10 8

42S 0

11 0 0 433 112

441 0

114 0 449 116 0 4S7 Rear clutch Number of drive

plates

4

Number of driven plates

4

Clearance Thickness of retaining plate Low

reverse

mOl

inJ

mOl

in

1 0 to

5 0 039 to 0 OS9 1

4 8 0 189

brake

Number ofdrive Number

plates

fdriven pla

4

Clearance Thickness of retaining

4

es

plaie

mOl

in

mOl

in

0 80 to 10S 0 0315 to 0 0413 118 0 46S 12 0 0 472

12 2 0480 12 4 0 488 12 6 0496

12 8 O S04 Brake band

Piston size

Big S

mOl

in

dia

64 2 S2

all dia

40 1 57

Control valve assembly

Stamped

mark on slraine

E

Governor assembly

Stamped

mark on governor

body

35

60 AT

Automatic Transmission Engine Idling

and stall revolution

Idling revolution

rpm

6S0 ai

Stall revolution

rpm

2 000 to 2 200

TIghtening torque

kg

Drive plate

to

crankshaft

Drive

to

torque

plate

Converter

housing

to

14 0 to 16 0

29

engine

4 0 to S O

29 10 36

4 S to 5 5

33

Transmission

case to rear

to converter

Oil pan to transmission

housing

extension

case

Servo piston retaine T to transmission

adjuting

Control valve

case

band brake

body



to

14

O S

to

0 7

4 to S

OS

to

07

4 to S

4 0

to 18

9 to 11

I I to

9 to 13 4 to S

0 25 to

3S O

2 to 3

Side plat

0 25 to

35 0

2 to 3

Nut for control valve

bolt

O S to 0 7

4 to S

Oil strainer to lower valve body

0 25 to

2 to 3

Governor valve

D S 100 7

4 to 5

0 6

to

0 8

4 to 6

5 0

to

0 7

4 toS

Oil pump

body

housing

to

reamer

to

oil distribu tor

oil pump

cover

Inhibitor switch to transmission Manual shaft lock Oil cooler

pipe

case

nut


Test plug oil pressure inspection hole

Support Oil

actuator

I

charging pipe

Dust

parking rod inserting position

cover

to rear extension

to case

to converter

housing

Selector range lever to manual shaft

Turn

back

two turns after

35 0

3 0 to 4 0

22 to 29

3 0

22 to 36

to

S O

I 4to 2 1

10

0 8 to I 1

6

61 AT

to IS

to

8

5S O

to 0 7S

4 to S

5S O

to 0 75

4 to S

3 0 to 4 0

tightening

29

3 to 1 8 1 0 5S to 0 75

control valve body

40

S

Lower valve body to upper valve body to

36

to

5 to 1 race

to

2 0

2 to 15 1

nut

One way clutch inner

101 to 116

4 0 to 5 0

case

Piston stem lock

ft lb

converter

Transmission

Pislon slem when

m

0 position

22 to 29


SPECIAL SERVICE TOOLS Tool number

Description

No tool

name

ST2S0SS001

Use for checking

hydraulic

For

Reference

use

page

on

Figure No

3N71B

pressure

Fig

or

AT 11 2

and Oil pressure gauge

3N71A

set

AfT

SE119

2

ST07870000

3N71 B

Use for setting transmission

Page AT 36

AfT Transmission case

stand

SE120

3

ST2S850000

Use for

removing

3N7IB

oil pump

Fig

AT S6

and

Sliding

hammers

3N71A

AfT J JIB

SE121

4

ST2S42000I

Use for

assemblilJg

or

disassembling

front and

3N71B

rear clutch

and Clutch

Fig AT 79 Fig AT 86

3N7lA

spring

AIT

compressor

SE 122

S

GG93010000

Use for

tightening

Max torque

Torque wrench

Drive

angle

46

3N71B

correct torque

kg

m

and

0 33 ft lb

3N71A

3 8 square

AlT

SE123

62 AT

Fig

69 AT


Tool number No

Description tool

6

name

ST2S490000

Socket extension to connect torque wrench GG93010000 W square socket wrench

with

For

Reference

use

page

on

Figure

3N71B

or

No

69 AT

Fig

AIT

Socket extension

V SE124

7

ST2S160000

Use for tightening Max torque

correct

1 04

kg

m

3N71B

torque

A T

90 ft lb

Torque driver

Fig Fig

AT 107

Fig

AT S9

AT 108

and 3N71A

3 SE125

8

HT69860000

Use for removing and

3N71B

replacing snap ring

and

Snap ring

remover

3N71A

AIT

SE126

9

ST2S320001

Use for removing and

3N71B

replacing snap ring

and

Snap ring

remover

Fig AT 79 Fig AT 86

3N71A

AIT

SE305

10

ST2SS70001 Hex head extension

Use for removing and torque wrench Drive

angle

installing

W square and 6

3N71B

way clutch inner race with

one

AIT mOl

across

flat width

SE128

AT

I

Fig Fig Page

64 AT AT 69

42 AT

AutomaJic Transmission

Tool number No

Description tool

II

name

HT623S0Q00

Use for

disassemlbing

and

assembling

control valve

For

Reference

use

page

on

Figure No

3N71B and

Spinner handle

Fig Fig

or

AT IOI AT I04

3N71A

AIT

SE129

12

HT61000800

Hexagon

Use for

disassembling

and

assembling

control valve

3N71B

wrench

AT IOI

and

Fig Fig

3N71A

Fig AT I07

AT 104

AIT

Fili

AT 108

3N71B

Fig Fig

AT 98

0 SE130

13

ST2SS80000

Use for centering oil pump

and Oil pump Ssemlbing l

3N71A gauge

AIT

SE131

AT 1l A

AT 99

0

SECTION PD


PROPELLER SHAFT DIFFERENTIAL CARRIER

PROPELLER SHAFT AND CENTER BEARING DIFFERENTIAL CARRIER

TYPE H19D TROUBLE DIAGNOSES AND CORRECTIONS

PD 2 f

PD 5

PD 14 I

SERVICE DATA AND

PD 16

SPECiFiCATIONS SPECIAL SERVICE TOOLS


LTD JAPAN

PD 19

PROPElLER SHAFT

DIFFERENTIAL CARRIER

PROPELLER SHAFT AND CENTER BEARING CONTENTS CHECKING AND CORRECTING

DESCRIPTION

PD 2


PD 2

UNBALANCED PROPELLER


PD 3

SERVICE

INSPECTION

PD 3

TROUBLE

SHAFT

3 PD

DATA

4 PD

DIAGNOSES AND

CORRECTIONS

i

4 PD

2

tl J I O

t I

148 5 5 85

483

750 987

19 02

53 29

35

38 86

38 1

Long wheelbase 1

Sleeve yoke assembly Center bearing

5

Companion flange

6

Plain washer

10

Center bearing insulator 4 Center bearing bracket

7 8

Self locking nut

11

2 3

9

The

shaft

propeller joint type The propeller shaft and universal joint assembly is carefully balanced during original assembly that is the on

the

620

series is 3

dynamic unbalance is under 49 0

in oz

If the

propeller

assembled so

that

at S 800

cm gr

Raise vehicle both

on

on

hoist Put match

propeller

in

ctional Crou

v

w

of propelkr hafl

3 Remove bolts connecting shaft to companion flange of differential car rier See Figure PD 3

shaft and

companion flange so that shaft can be reinstalled in the original position 2 Remove bolts retaining center

bearing bracket See Figure

rpm

PD 2

shaft has to be

it must be made

the above

35

I

mm

PD218

PD l

REMOVAL AND INSTALLATION marks

Unit

Bearing race assembly Snap ring Journal assembly

Flange yoke

Fig

DESCRIP TION

and

Deluxe cab models

Rea

Front

carefully

limit is not

ex

ceeded Therefore when the vehicle is to be undercoated

cover

the

propeller

PD220

shaft and universal joints to prevent application of the undercoating ma

Fig

PD 3 Removingpropclkr

t cha

terial 4 PD219

Fig

PD2 Removing center

bearing bruckel

PD 2

Withdraw

yoke from

shaft rearward axle

propeller

transmission

shaft sleeve

by moving passing it under rear


PROPELLER SHAFT leakage from

Watch for oil

trans

Note

not to

as

and

yoke

shaft carefully

careful

damage

not to

damage spline sleeve

When disassembling and repairing center bearing are required the follow

oil seal

ing procedures

propeller

Remove

rear

b Plug up the opening in the rear

extension

oil from

removal

to

housing

flowing

install

To

from

removing journal

journal and yoke bole

Notes

so

be

yoke

mission end

a

When

rear of

prevent

out the

reverse

foregoing

procedure

applied

Put match marks

1

Align propeller shaft with com panion flange using reference marks in removal

kg

I Drive

Pinion

Flange

ing nut and Figure PD 5

remove

center

bearing

See

assembling

pro

follows

Install center bearing in center

bearing insulator bearing assembly

center

2

Install

and

companion flange

Flange Wrench specified torque

on

front shaft

ST3IS30000 to

Pinion

m

Insert bolts through the holes of

Tightening torque

beariug bracket and torque nuts retain center bearing on cross

center to

are as

usiug reference marks established in disassembly procedure 3 Install washer and locking nut on front shaft and tighten nut using Drive

17 to 24 ft Ib 2

adjust unbalance less than 3S 800 S rpm

flange Applying

in lb

49 in oz at 0 gr cm Center bearing cedures

Tightening torque 3

13

propeller shaft Remove bolts connecting flange yoke to companion

assemble with bolts

4 to 2

em

so

When the above steps are complete place the shaft in a balancing machine

flange and

and

procedure

kg

front

2

assemble components

that joint moves under friction resistance of less than is o

and

on

Wrench ST3lS30000 loosen off lock

1

prescribed

are

Install and

correctly

20 0 to 24 0 kg

m

I4S to 174 ft lb

member

Tightening torque 1 6 to 2 2

12

kg

m

do not disassemble pro shaft because it is balanced as an

Primarily

Tightening torque To

assemble

reverse

the foregoing

procedure using reference marks scribed in disassembly procedure New

bearing need

recommended

Fill joint

check propeller shaft journal for movement When journal does not move smoothly dis

with

grease whenever overhauled

assemble

Use related snap rings of the same thickness and be sure that play is

so

propeller the original

Mark that

shaft and

journal

combination

Remove snap ring with screwdriver

a

standard

in

Install center

center

Thickness mm

in

i

bracket

on

for dent

or

bearing

bearing

is

INSPECTION Check

I

journal pin

brinell marks

and yoke hole for sign

ring

Snap ring should also be

bearing and seal ring

inspected to

Color

damaged worn place if necessary

identification

2

or

see

if these

deformed

White

2 02 0079S

Yellow

insulator cannot be tolerated here

Red

3

2 06 0 08 II

Green

face

2 08

0 0819

Blue

necessary

10 2

0 0827

Right Brown

12 2

0 83S

No paint Pink

bearing PD 3

Check for

is

by rotating rough noisy or

2 00 00787

2 14 00843

Re

heck center bearing

bearing race If it damaged discard

Q4 0 0803 2

PDOO5

kg m

to 24 ft Ib

of wear or damage

Available snap

4 PD

Fig PD 4 Remo

S

are

3 Lightly tap base of yoke with a hammer and withdraw bearing race See Figure

shaft

can

be restored at assembly 2

below 0 02 mm

propeller

0 0008

17

multi purpose

with

However

2 4 to 3 3

pre

not be lubricated

since it is lubricated for life

assembly

1

and

torque

DISASSEMBLY AND ASSEMBLY peller

flange of front f1ange yoke of rear shaft tighten connect bolts to specified

shaft with

nut Fig PD 5 Remouing locking

to 16 ft Ib

Join companion

4

ST31530000

P0172

Cracked

propeller

dent

or

bearing

shaft tube

crack

sur

Change if

PROPELLER SHAFT 8l DIFFERENTIALCAAR ER CHECKING AND

anced

propeller

shaft

proceed

as

CQRRECTING UNBALANCED

follows

PROPELLER SHAFT

foreign materials which could upset

Remove

I

undercoating and

and check shaft vibra

shaft balance To

check

and correct

unbal

an

other

tion

by road

2

If shaft vibration is noted

test

road test

disconnect propeller shaft at

differential carrier companion rotate companion flange 180 and reinstall

propeller

3

check

Again

vibration

during

peller

still

shaft

flange degrees

shaft

shaft vibration

persists

replace

assembly

SERVICE DATA Pe issible dynamic unbalance Axi

gr cm in

play of spider journal

mm

Journal swinging torque

Propeller

kg

shaft front and

out of round

rear

in

0 49 at S 800 rpm

Less than 0 02 0 0008 in Ib

em

mm

3S

oz

Less than IS O 13

in

Less than 0 6 0

024

Tightening torque Shaft to conipanion

flange

Gear carrier bolt

Self locking nut front shaft

Flange yo

e

rear shaft

to

companion flange

front shaft bolt Center

bearing

bracket to

cross member

m

ft lb

2 4 to

kg m

ft Ib

20 0 to 24 0 l4S to 174

kg

m

ft lb

2 4 to 3 17 to 24

kg

m

ft lb

kg

bolt

3 17 to 24

1 6 to 2 2

12 to 16

TROUBLE DIAGNOSES AND CQRRECTIONS Condition Vibration medium

during at high speed

or

Probable Worn

or

damaged

Corrective action

cause

universal joint

needle

Replace

propeller

l I eplace

bearing Unbalance due to bent

or

dented

shaft Loose

propeller

shaft installation

Worn transmission

Damaged Tight

center

rear

extension bushing

bearing

or

insulator

universal joints

Undercoating

or

mud

Retighten

Replace Replace Impact yokes with hammer to Replace joint if unable to free up feels rough when rotated by hand

on

the shaft causing

free or

up ifjoint

Clean up shaft

unbalance Tire unbalance

Balance wheel and tire from known

Balance weights missing

Replace

PD 4

good

assembly

vehicle

or

If

pro

replace


PROPELLER SHAFT Condition

Probable

Knocking

Worn

sound during starting or noise during coasting on propeller

damaged

Worn sleeve

shaft

Corrective action

cause

universal joint

yoke

Replace

and main shaft

spline

Replace

Loose

propeller shaft installation

Retighten

Loose

joint installation

Adjust

Damaged Loose

missing bolts

at

center

ring

Replace

center bearing or insulator

or

snap

bearing

Replace

or

tighten bolts

bracket to body

Scraping

noise

Dust

cover

transmission

sleeve

on rear

yoke rubbing

extension Dust

companion flange rubbing

on

c

Straighten

on

dust

out

cover

to

remove

inter

ference

ver on

differ mtial

carrier Whine

or

whistle

Damaged

center

bearing

Replace


H190

TYPE


PD

5

ASSEMBlY OF

REMOVAL

PD

7

CASE

PRE DISASSEMBLY INSPECTION

PD

7

ADJUSTMENT

DISASSEMBLY

PD

7

HEIGHT

INSPECTION

PD

8

ADJUSTME NT OF DRIVE PINION

ASSEMBLY AND ADJUSTMENT PRECAUTIONS IN

PD

REASSEMBLY

ASSEMBLY OF DIFFERENTIAL CASE

8

PD

8

ADJUST

PD

8

PD

9

OF DRIVE PINION

PRELOAD t

PD

DIFFERENT Al

PD lO ENT

OF SIDE

8EARING PD 11

SHIMS

PD 13

INSTAllATION

REPLACEME NTOF

PD 13

FRONT Oil SEAL

DESCRIPTION The differential carrier series

has a gear

ratio of

on

the 620

37S 4

The drive pinion is rnounted in two

tapered

roUer bearings which

are

pre

loaded

by pinion bearing adjusting spacer and washer during assembly The drive pinion is positioned by a washer located between

a

shoulder of

the drive pinion and the rear bearing The differential case is supported in the carrier

bearings

by

two

These

are

tapered

roller side

preloaded by in

serting shims between the bearings and the differential case The differential is

for proper ring gear and drive pinion backlash by case

assembly

positioned

varying bolted case

these shims to

the

The

differential

houses two

ring

gear is

case

with two pinion mates mounted

pinion

shaft The

chored in the

pinion

The

side gears in mesh

case

on a

pinion shaft an by lock pin The

mates and side gears are backed

by thrust washers The carrier is of malleable cast iron

PO 5

PROPEllEff SAAFT

8

CARRIER

DifFERENTIAL

TYPE H19O

Q@

4

@

nut

1 2

Drive pinion

3

Oil

4

Front bearing

Companion flange al

adjusting washer DIive pinion bearing bearing preload by

5

Adjust pinion ecting @ and @

@

Drive

1

Drive pinion

8

Rem

9

Drive pinion

10

loci pin

@

bearing

and cIrive

@@

@

spacer

adjusting

wamer

mint Side bearing adjusting and preload bearing side Adjust geu betwam ring backlash

11

@

pinion beating

6

12

Side bearing

13

Side gear nUust washer

14

ting @

pinion by

to side

mate Adjust pinion backlash Of the clearance

face of side between the teat to 0 02 to washer ttuust gear and in 0031 10 0 0 08 nun 0 0008

@

@

gear

15

by@ Differential

16

Thrust washer

17

Pinion

18

Pinion sbaft

19

Ring gear Backlam between ring gear

20

cast

mate

and drive pinion 0 t5 to 0 20 nun in 0 0059 10 0 0079 boll cap Bearing

21 22

Thrust block Ring gear bolt

23

Lock strap of torque f m ft lb bollS and nut kg

Tightening

@

L

101 to 123 14 0 to t7 0 36 4 0 to 5 0 29 10

@T @T @T

7

58 0108 0 5110

4010 198

L 1

198 55

nun

8110107 8169

in

P0229

Fig PD 6

6 PD

croectional

uiew of differenwl

carner


PROPELLER SHAFT

I

Jack up

port

it

rear

by placing

a

shaft and

axle shafts These works

by referring Suspension

under

safety stand

propeller

Remove

2

of vehicle and sup

Drain gear oil

rear axle case

can

rear

I

Put

match

and

tpark

caps bearing caps and case assembly

on

and

carrier

Hold

rear

bearing inner race with Bearing Inner Race

Drive Pinion Rear side

bearing

remove side

Puller ST30031000 and extract from drive pinion with

a

press

take out differential

be done

Rear

Rear Axle and

to

5

DISASSEMBLY

REMOVAL

Loosen off bolts securing differ and rear axle cas

3

ential carrier to

STJ0031000

take out differential carrier assembly

PD205

PRE DISASSEMBLY

P0203

INSPECTION carrier should

Differential

spected before

any

parts

are

be in

case assem

bly

removed

from it These fmd the

inspections cause

of

a

are

helpful

to

Note

and to

problem

Mount differential carrier

on

Care

confuse

determine the corrections needed I

Fig PD 10 Removing pinion bearing inner

Fig PD B Removing differenlwl

should be the left

taken not to

and

right

hand

6

To

remove

front

and

drift

to

rear

race

draw them

with

a

outer

races

bearing apply

rear race

of both a

brass

side surface and with

by tapping the top of drift

hammer

bearing caps and bearing outer race so that reassembly will be easily

Dif

ferential Attachment ST063 I 0000

carried out with the

same

parts in

the original position 2

Remove

Drive

drive pinion nut using Wrench Flange

Pinion

ST31530000

flange using

a

and

pull off companion

standard

puller

Fig PD l1 Removing pinion front and rear bearing outer races

ST063 10000

Fig PD 7 Holding differential

Visually inspect parts for damage 2

canier

wear

or

Dissssembly of dHferentIeI case

Rotate gears to see if there is any roughness which would indicate dam 3

aged bearings

or

chipped

the gear teeth for

gears

scoring

or

1

ST3306S00 I

signs of Fig PD 9 Removing drive pinion

pinion See Figure Set up a dial indicator and check the backlash at several points around

nul

wear

Measure

preload

PD 19

drive

replacing

Differential

Check of

abnormal

When

Side

side bearing

use

Bearing Puller Set

set of ST330S100 I and

ST33061000

4

ring

gear

Backlash should be

15 0

to

0 20 mOl 0 00S9 to 0 0079 in S Check the gear tooth contact with a mixture of ferric oxide and

ring gear teeth For the tooth contact pattern see paragraph dealing with tooth contact g ar oil to all

pattern adjustment

3

Extract drive pinion assembly to by tapping the front end

the rearwards with

a

soft hammer Drive

be taken out

ing

nner

together with

pinion rear

can

bear

bearing spacer and

race

washer 4

Remove

seal and

oil

front bearing inner Note

take out

race

Oil seal must not be

PD 7

used

Fig PD 12 Removing ide bearing

PROPElli ER SHAfT Notes a

Note

PUller should be handled with in

the

catchins

of

edge

care

DIFFERENTIAL GARRIERf

Drive

and

pinion

ring

supplied for replacement

bearing

therefore

inner race

should

gear are as

a

either part

damaged replace as

a

set

2

I

set

Check pinion shaft

mate for scores and

2 out

Remove ring gear by spreading lock strap and loosening ring gear

replace

3

Punch ICV31100300

same

and their

gear

and pinic m wear and

signs of

required

Follow the

bolts in diagonally Punch off pinion mate shaft lock pin from ring gear side using Solid

as

procedure

seats

on

for side

differential

case

all

Inspect

and

bearing scoring chipping or evi dence of excessive wear They should be in tiptop condition such as not worn

and

Replace

races

with

mirror like

if there is

surfaces

their efficiency as an bearing operation may result

2

Fit

case

so

be

can

3

Adjust pinion

PD 13 Removing lock pin

Note

Lock

i cauIked at pin hole mouth on differential case Do not

punch

it

Draw

move

off

forCibly

how it is

checkins 4

pin

without

uIked

to

corrected

with

0 0031 in

replace thrust

S

Inspect

case

for cracks

condition

is

carrier or

and

evident

If either

replace faulty

parts As a

6

general rule oil seal should be replaced at each disassembly

Assembly verse

ing a

Thickness

8re

worn

faulty Repair

and or

whichever is I

damaged how they are affected replace ail faulty parts necessaiy

Check

cracking

if they

and

or

gear

teeth

chipping

otherwise

for

scoring

and make

sure

that tooth contact pattern indicates correct

evident

meshing depth If any fault replace parts as required

is

nun

in

Over 0 7S to 0 80 0 029S to 0 03IS Over

80 0

to

8S O

Om IS to 0 033S

Over 0 8S to 090 0 033S to 003S4 Over 090 to 0 9S 0 03S4 to 0 0374

Lock pinion shaft lock pin using punch after it is secured into place S

Apply

a

oil to gear tooth surfaces

and thrust surfaces and check if they turn

6

properly Place ring gear

and

install bolts

Torque

bolts

on

differential

and lock

case

washers

specification

to

7 0 to 8 0 kg

S1to

be done in the

can

and

directions

for

adjustment

Sifft

m

Ib

reo

order of disassembly The foDow and

perfect differential operation

Notes ao

Use and

b

gear bolts

only genuine ring new

lock strap bolts in

cross criss Tighten lighdy tapping fOund

with

see

side gear

Side gear thrust WlISber

INSPECTION disassembled

by selecting

Tightening torque

usage of special tools enable to obtain

clean all

in

thrust 0 0008

bend up lock strap

ADjUSTMENT

Thoroughly

and

4

differential

distortion

Note

parts and examine them to

of side gear

to 0 02 to 0 08 mOl

0 0031

gear

thrust washer

sand

washers

ASSEMBLY AND

ed in their original positions from which they were removed

toide

mate

the clearance between the

side gear and thrust washer exceeds limits 0 02 to 0 08 nun 00008 to

gears and thrust washers

gear and thrust Wasliersotliat they can be reinstaD

differential

to

in noises

pinion shaft and re thrust block pinion mates side

on

or

incorrect

out

Put marks

pinion shaft

face

washer

paper If pinion mate toide gear backlash or the clearance between

Fig

side

that it meets lock pin holes

backlash

and gear seizure 4 Inspect thrust washer faces Small

faults

mates

pinion

gears thrust block and thrust washers in differential case

shadow of doubt

a

oil

PD022

Assemble

rear

3

rollers for

KV31100300

DIFFERENTIAL CASE

be

b Be careful not to confuse left and

right hand parts

ASSEMBLY OF

fashion bolt

Js heac

a hammer

PRECAUTIONS IN REASSEMBLY I

Arrange shims

like to install them 2

Thoroughly

which shims

w

shers and the 7

correctly

clean the surfaces

washers

bearings

on

and

bearing caps are installed 3 Apply gear oil when installing bearings 4 Pack grease cavity between lips when fitting oil seal 8 PD

When

replacing

side

bearing

bearing width using a stand 20 00 nun 0 7874 in gauge

measure

ard

thickness S S

Ib

Figure

and

prior

a

weight to

block

installation

PD I4

Standard bearing width 20 00 nun 0 7874 in

5 2

kg

See

DifFERENTIAL CARRIER

PROPELLER SHAFT

Where

Rear

ST306 II 000 and

T

Required thickness of rear bearing adjusting washers mOl

N

Measured

ST3062I 000 I

1 2

Fit

rear

on carrier and

bearing

install Dummy Shaft Sf3 I 942000 and Standard

Collar ST3197oo00

gauge

and on

place

on

Height Gauge ST31941000

with

thickness

Figure marked on the drive pinion head See Figure PD 18 Figure marked on the dummy

H

bearing

rear

value

mOl

gauge

0

carrier

shaft marked

Figure

S

the

on

height

gauge ST31941000

uring bearing width Me

Fig PD 14

and S

0

Figures for H

sional variations in

a

are

unit of 1

dimen

100

mOl

against each standard measurement 8

Press fit side bearing cone into case using Differential Side

differential

Bearing Drift ST33230000 and Adapt er

ST33061000 Set numblr

PD2 b

J t

Head

Fig PD 16 Adjusting pinion height

ST33230000

number HI

I

P0186

3

io o1

Measure

the

clearance

N

be Fig PD 18

the tip end of height gauge and the end surface of dummy shaft using tween

thicknes a

Variation number

on

drive pinion

gauge

Examples of calculation P0244

I

Ex Fig PD 15 ln talling side bearing cone

N

0 5Imm

S

O

T

N

H

D

H

0

2

1

xO 01

S

2 18

ol O

Adjust washer

the

ld a

Press fit races

Drive Pinion

51 0

with

height

Fig PD 17

bearing the back of pinion gear

provided

inner race

outer

pinion

between

2

rear

0

t 1

x

0

01

18 2

P0235

PINION HEIGHT

0

18 2

O SI

ADJUSTMENT OF DRIVE

I

2

51 0 x

51 0

Measuring clearance

3

x

0 03

2 18

0 01 18 2

2 66 mOl

front and rear bearing into gear

carrier

using

Ou ter Race Drift Tlie

4

thickness

of drive

height adjusting wa shers tained from the

following

can

pInIOn be ob

formula

Front ST306 I 1000 and Sf30613oo0

T

N

H

0

2 18

PD 9

S

x

0 01

The thick

correct

See

washer

is

table

following pinion adjusting washer

2 67 mm

for drive

PROPELLER SHAFT Ex 2


Drive pinion

N

O 68mm

3

H

D

washer

Note

I

N

H

0

S

3

Om

x

2

1

2 61

0 1028

2 64

18 2

0 68

0 1016

0 01

x

218 068

58 2

3

1

2

0 01

x

heing tightened

select

0 1063

2 73

0 107S

pinion by hand while it

Measure pinion bearing prelo d using Preload Gauge ST3I 27S000 and

1051

70 2

and

2

1039 0

2 67 0

washer

bearing

with thicker ones if

cannot be turned

in

mm

is T

Replace

spacer Thickness

2

S

adjusting

washer

and

spacer

that will

provide required preload

18 2

0 68

2

0 68

i88

2 18

02 0

2 79

0 1098

82 2

0 1110

mm

is

washer

correct

1087 0

2 76

N8

02 0

0 68

The

18 2

0 01

x

Preload

2 85 OJ 122

2 88 mm

thick

2 91 0 70mm

N S

H

O

0

0

O

T

N

H

0

S

0 70

0

0

0

x

0 01

2 18

0 70

0 x 0 01

0 70

0

0 70

2 18

2 18

2 97

1169 0

3 00

1181 0

kg

4 to8 2Ib 6

Note

1205 0

Preload

same

3 09

0 1217

3 12

0 1228

3 IS

0 1240

3 18

0 I2S2

of old

bearing is the

value as that of a

new

bearing

2 18

2 88 mm

The

1IS8 0

3 06

2 18

companion flange bolt hole 2 9 to 3 7

3 03 0 1 193

0 01

x

At

0 1146

2 94

cm kg

8 7 to II in lb

2 88 OJ 134

Ex 3

without oil seal

10 0 to 13 0

S

washer

correct

2 88

is

mm

thick

Fit

determined drive pinion ad

justing washer fit

preSs

rear

in

drive pinion

bearing

and

inner race in it

using Base ST30901000

ADJUSTMENT OF DRIVE Note are

lues signifying H D and S

If not

and

given regard C

n

check to correct

tooth

r

see

e

them

After

as zero

assembly

that tooth contact is

If not contact

readjust pattern

PJ 12 for Contact Pattern

For the see

page

IPIENLOADIONPI AdjUst the preload of drive pinion with spacer and washer between front and

rear

Fig PD 19 Measuring pinion preload

bearing inner races

This procedure has nothing to do with thickness of drive pinion adjust

ing washer This

adjustment

be carried

must

Pinion

bearing adjusting

spacer

out without oil seal inserted I

Lubricate pinion front and

bearings carrier

front

flange

rear

Install drive pinion in gear Be sure that spacer washer t

bearing

inner

race

and flat washer

pinion Tighten and confum

nut to

are

fitted

14S7 2

S4 80 2 IS7S SS IO 2 1693

SS 70 2 1929 m

to 123 ft lb

PD l0

in

5S 40 2 1811

Tightening torque 14 0 to 17 0 kg

50 S4

mOl

on

specified torque

preload

101

Companion

Length

S6 00 2 2047


PROPELLER SHAFT Drive pinion

bearing adjusting

T

washer

A

C

D

B

T2 Thickness

mm

over

3 80 to 3 82 0 1496 to

over

3 82 to 3 84

84 3

over

86 3

to

lS04 O

Ex

A

F

to 0 ISI2

T1

to 0 IS20

bearing adjusting shim mm T2 Required thickness of right side bearing adjusting shim mm A Figure marked on the left side bearing housing of gear carrier B Figure marked on the right side bearing of gear carrier 0 C Figure marked on the differ

lS20 O

to

3 88 to 3 90

lS28 O

to 0 IS3S

O IS28

over

3 90 to 3 92

over

3 92 to 3 94 0 IS43 to

over

3 94 to 3 96

lSSI O

to

over

3 96 to 3 98

lSS9 O

to 0 IS67

over

3 98 to 4 00

lS67 O

to

0 IS3S to O IS43

4 00 to 4 02 0

S7S to

lSS O

I

lS59 O

lS83 O

E

the

or

standard

width

20 00

4 06 to 4 08

lS98 O

to 0 1606

If bearing width is 19 89 the differ

over

4 08 to

1606 0

to

ence

1614 0

will be

20 00

oil

n

press

seal into gear

carrier

Tool Fitting KV38I02SS0 Apply grease cavity be tween seal lips Oil

using

H

Unless

companion flange and Seal

Again install companion flange and washer and tighteh nut to speci to fied torque 14 0 to 17 0 kg IO m

as

Measure

S

Preload

preload again

with oil seal

I 1 0 to 14 0

cm kg

1

flange

4

Figures

for A

dimensional 1

100

mm

B

C

varia tions

in

a

unit

against each standard

can

0 175 1 7S 0

11 0

0 11

mOl

The correct shims Thickness

are as

follows

Quantity

07 0

x

2

0 14

0 20

x

I

0 20

34 0

Total thickness

rj

f

71

Right

side

T2

B

0

H

mOl

3

2

Markj

2

O ISO

Mark B 2

3

O ISO 3

x

0 27 The

of shim on l ft and righ t sides

gear set carrier dif side bearing has been

Fig PD 21

Variation number

ing formulas

on

ring gear

PD ll

20 0

correct

mm

thick

0 01

x

0 01

0 15 2

0 01

x

0

O OI

0 03 Mark C 0

x

F

lSO O

bolt hole

be calculated by the follow

OO

a

@

replaced with new one adjust the side bearing preload with adjusting shim The required thickness of adjusting shim

x

0 11

0 01

32S 0

meas

ADJUSTMENT OF SIDE BEARING SHIMS

case or

2

urement

Fig PD 20 Thickn

hypoid

x

of

P0214

If

0 01

1 0 11

3

0 04

0 and H are

6 8 to 8 81b

I

3

2

x

0 01

x

0 11

19 89

1 to 4 0 kg 3

ferential

2

1

H

E

0 17S

9 S to 12 in lb At companion

0

follows

Figure marked on the ring gear See Figures PD 20 and PD 2 I

4

123 ft lb

C liS O

is found remove drive

nut and

pinion

completed

mm

mOl

3

is

A

T

mOl

to 0 IS98

bearing preload anything wrong

O IS

Left side

right side bearing against

lS9I O

Check and adjust tooth contact pattern when former adjustment of

2

3

0

2

C F

l7S O

4 04 to 4 06

10 4

H

2

mm

case

over

over

B

0 11

These are differences in width

F

of left

to 0 IS91

lS83 O

I

E

thickness of left side

Required

entia

lS7S O

I

xO OI

lSI2 O

3 86 to 3 88

4 02 to 4 04

H

lS04 O

over

over

Examples of calculation

xO OI

Where

over

over

D

O ISO

in

H

E

l7S O

15 O IS

O ISO lSO O

lS O

mm

shims

are

0 07

plus

PROPELLER SHAFf Ex 2

2

A

0

3

B

C

0 20 mOl

E H

I

F

0

0 17

Fit

determined

adjusting

0

mOl

2

DIFFERENTIAL CARR IER

shim

on

side

differential

press

fit left and right side

inner

races

and

bearing

it

using Side Bearing ST33230000 and Adapter

Drift

on

ST33061000 3

Left side TI

A

C

D

0 17S 0

0

0 I7S 0

I

0 03

17S 0

Align

that

on

a

rubber

Thoroughly

mark

on

bearing

cap with

gear carrier and install

And tight

n

bearing

bolts to

Paint ring gear teeth lightly and a mixture of ferric oxide

and

gear

3

to

Rotate

produce

contact

a

pinion through several

directions until

0 20

Tightening torque 4 0 to S O kg m

a

reverse

defmite contact pat

tern is 4

29 to 36 fHb

rect

thick

developed on ring gear When contact pattern is incor readjust thickness of adjusting

washer

Right side

Incorrect can

be

contact

adjusted

pattern

in the

of

following

manner

B

H xO 0l

D

O ISO 3

0

3

0 150 x

drive to

pinion

If backlash is too small

om

right

side To reduce backlash

shims from

0 ISO

remove

shims from left side and add them to

0 I7

right

remove

side and add them to

left side

0 17

a

Heel contact To

correct

increase

thickness of

pinion height adjusting washer in order to bring drive pinio close to ring gear

mrn

shims

correct

1 0 plus 0 20 0

x

1S0 0

37 0

om

17 0

001

O OS

x

0 17 2

Measure ring gear

backlash

2

0

S

F

O ISO

The

oil

pattern

S

S

clean ring and drive

evenly with

teeth

T2

con

drive

pinion gear teeth

revolutions in the forward and

shinjs are O OS plus

0 20 mrn

pattern of ring gear and

I

assembly

0 20

0 17S

with side bear

Check and adjust the tooth

tact

specified torque

mrn

correct

plus

0 01

x

case

tapping with

cap on carrier

0 20

O 34S The

2

0

Om

3

0 01

x

0 20

17S 0

0 10

2

7

2

4

it

ing shims

mallet

E

I

specification adjust

pinion

Install differential

into gear carrie

H x om

If preload does not accord with this

bearing case

mm

are

Backlash

0 07 plus

1S O

thick

to

0 20 mrn

000S9 to 0 0079 in

Note

If w1ues

and H

are

signifying A given regard

not

and compute Aftassembly check to

B

C 0

them

P0193

Fig PD23 Hul contact

as

zero

preload and backlash not readjust

are

see

that

correct

If

b Toe contact To Side bearing

adjusting

Thickness

shim

mm

O OS

00020

0 07

00028

correct

reduce

thickness

of

pinion height adjusting washer in order to make drive pinion go away from ring gear

in

Fig PD 22 Mccuuring back1aah

At

6

bearing

the

same

preload

time

check

Bearing

10 0

0 0039

0 20

00079

should read 12 0 to 20 0 17 in lb of

50 0

00197

S 8

cm kg

rotating torque

kg

side

preload 10 to 3 S to

7 7 to 12 8 Ib at ring gear bolt

hole

1

P0194

Fig PD 24 To

PD 12

contact


P ROPELLER SHAFT Flank oontact

c

Adjust

in the

INSTALLATION same

manner as

in

b

Installing

can be done in the reverse

order of removal

Tightening torque Gear carrier to

cV t

rear

5 kg 2

17 to

axle

case

m

12 to 18 ft lb Drain and filler

PD195

6 0 to 10 0 kg

Fig PD 25 Flank contact

P0238

plug

Fig PD 29 Removing companion

m

flange

43 to 72 ft lb 10 liter

Gear oil capacity 2

US

pt

I Y

Imp pt

d Face contact

Adjust

6

Remove oil seal

7

Set

oil seal in position using Fitting Tool KV38102SS0

new

Oil Seal

in the same manner as in a

REPLACEMENT OF FRONT OIL SEAL Replacement of front oil seal with carrier assembly installed on the vehicle

w

difer ntial

When

replacing

front oil seal do

as

P0196

Fig PD 26 Face contact

1

Drain gear oil

2

Raise the rear end of vehicle and

support it with safety stands 3 Detach propeller shaft from

panion flange of

sher

secure

them in position by tightening

nut to

the

given

preload

drive pinion

flat

and

on

torque confirming specified using Drive Pinion Flange

WrencliST31530000

follows

t

grease in between seal lips Fit companion flange and

Apply 8

Tightening

torque

14 0 to 17 0

com

kg

101 to 123 ft Ib

carrier

Pinion bearing preload

4

Rove drive pinion n t holding 1 companion flange with Drive Pinion Flange Wrench ST31S30000

with oil seal 110 to 14 0

cm kg

5 to 12 in lb 9 At companion

flange

bolt hole

1 to 4 o g 3 6 8

e

8 8Ib

Correct tooth contact

Notes a

Preioad value as

of old bearing is the that of a new bearing

b If the desired nut can

P0237

same

tightening torque

ot be obtained renew nut and

readjust Fig PD 28 R moving drive pinion

Fig PD 27 Correct contact

nut

Note

ing

Change

in thickness of

washer

is

adjWll accompanied by

change in backlash Oled it when instaIIi gear

S

Extract companion flange using

standard

a

8

Reinstall

propeller

shaft

and fill

up differential carrier with gear oil

puller PD

13

PROPELLER SHAFT

DIFFERENTIAl CARRIER

TROUBLE DIAGNOSES AND CORRECTIONS When

differential carrier is

a

pected of being noisy it make a thorough lest whether the noise

tires

sus

is advisable to to

determine

originates

in the

surface exhaust

carrier Noise which

Condition

Noise on drive

road

universal

places

joint propeller shaft wheel bearings engine transmission or differential

Probable

Shortage

originates

cannot be corrected

replacement

ment or

by adjust

of parts in dif

ferential carrier

in other

cause

Corrective action

of oil

Supply

coast and float

oil

gear

Rebuild

gear

carrier

if

necessary Incorrect tooth contact between

ring

gear

Adjust

tooth contact

and drive pinion

gear set

Incorrect backlash between ring gear and drive pinion

Adjust backlash

Seized up

damaged ring gear and drive

or

or

or

replace the hypoid the

replace

hypoid

gear

set if necessary

Replace

the hypoid gear set

Replace

the pinion

Replace

the side bearing and

pinion Seized up

damaged

or

damaged

or

broken drive pinion

bearing

and faulty parts

bearing Seized up Loose bolts

or

nuts

broken side

fIXing ring

gear

bearing bearing

cap etc Noise

on

turn

Seized

up

pinion

mate

damaged

Seized up damaged pinion thrust washer

or

Pinion mates too tight

Knocking starting

or

sound gear

during shifting

or

broken side and

broken side gear and

on

their shaft

them to

Clamp faulty parts

faulty parts

specified torque

and


Replace faulty

parts

Replace faulty

parts

Excessive backlash Incorrect

pinion

or

backlash

Worn gears Worn

ring

ar

to drive

rear

or case

axle shaft and side gear spline

Drjve pinion bearing

under preload

cap

or

nuts

ftxing ring

gear

etc

PD 14

Replace

worn

Replace

worn parts

parts

Adjust preload

Loose drive pinion nut Loose bolts

Adjust backlash

side gear to pinionmate

bearing

Repair

or

Clamp

them

replace or

replace

if necessary

replace

PROPELLER SHAFT

IFFERENTIAl CARRIER

1

Condition

Seizure of breakage

Probable

Shortage of oil

or

use

j

Corrective action

cause

of unsuitable oil


and use reconunended

gear oil

Excessively small backlash Incorrect

adjustment

Severe service

improper

Adjust backlash and replace

of bearings

leakage

damaged

front oil seal

mally

worn

loading


or

or

as

ring

gear bolts


improperly

bruised dented

or

driven abnor

slide face of companion flange

Replace faulty oil seal Repair the affected flange with sandpaper or replace if nee essary

Tighten

Faulty gasket

Replace faulty gasket with

Clogged

or

required


Loose gear carrier bolts

Loose fIller

as

of clutch

use

out Worn

gears

due to an excessive

Loose bolts and nuts such

Oil

or

or

drain

the bolts to

Tighten

plug

damaged breather

Repair

PD 15

the

or

plug

replace

specified torque new

one

PROPELLER SHAFT



Type

HI90

Ge ar carrier material

Malleable cast iron

Gear ratio number of teeth

4 375

3S 8

Spacer

and washer

Drive pinion

Drive

preload adjusted by

pinion cm in Ib kg

Preload without oil seal

10 0 to 13 0 8 7 to II

with oil seal

110 to 14 0

At companion

flange

olt hole

kg Ib 2 9 to 3 7

without oil seal

6 4 to 8 2

1 to 4 0 6 8 to 8 8 3

with oil seal Thickness of drive pinion

adjusting

washer

nun

in

2 S8 2 61

1016 0 0 1028

2 64 0 1039 2 67 0 IOSI 2 70 0 1063 2 73 O I07S 2 76 0 1087 2 79 0 1098 2 82 0 1110 2 8S 0 1122 2 88

2 91

0 1134

1146 0

2 94 0 1158 2 97 0 1169 3 00 0 1181 3 03 0 1193 3 06 0 120S 3 09 0 1217 3 12 0 1228 3 IS 0 1240 3 18 0 12S2

Length ofdrive pinion bearing

adjusting

spacer

5 to 12 9

nun

in

50 S4

2 14S7

54 80 2 IS7S SS IO 2 1693 SS 40 2 1811 SS 70

1929 2

S6 00 2 2047

PD 16

DIFfERENTIALCARRI ER

PROPELlER SHAFT

Thickness of drive pinion bearing

adjusting

washer

in

mm

over

3 80 to 3 82 0 1496 to O IS04

over

3 82 to 3 8

over

3 84 to 3 86

0 ISI2 to 0 IS20

over

3 86 to 3 88

0 1520 to 0 IS28

over

3 88 to 3 90 0 IS28 to 0 IS3S

over

3 90 to 3 92

over

3 92 to 3 94 0 1543 to O ISSI

over

3 94 to 3 96 0

over

3 96 to 3 98

IS04 to

HO

0 IS3S to

I5si

OcISI2

1S43 0

to 0 ISS9

0 I5S9 to 0 IS67

over

3 98 to 4 00 0 1567 to 0 IS7S

over

4 00 to 4 02

over

4 02 to 4 04 0 IS83 to 0 IS91

over

4 04 to 4 06

0 IS91 to 0 IS98

over

4 06 to 4 08

0 1598 to 0 1606

over

4 08 to 4 10

0 1606 to

over

0 7S to 0 80 0 029S to 0 03IS

over

0 80 to 0 8S

over

0 8S to 0 90 0 0335 to 0 03S4

over

0 90 to 0 9S

0 157S to 0 IS83

1614 0

Side gear and pinion mate Thickness of side gear thrust washer

Pinion mate to side gear backlash

in

mOl

0 03IS to 0 033S 0 03S4 to 0 0374

or

clearance between side gear and thrust washer

mOl

in

mm

in

0 02 to 0 08 0 0008 to 0 0031

Ring gear Ring

gear to drive

Thickness of side

pinion backlash

1S O

to 0 20

0 00S9 to 0 0079

bearing adjusting

shim

mOl

in

O OS

0 0020

07 0 0028 0 10 0

0 0039

0 20 0 0079 0 50 0 0197 Side bearing standard width

mm

kg m

TIghtening torque Drive

Ring

pinion

20 00 0 7874

in ft Ib

14 0 to 17 0

nut

7 0 to 8 0 SI toS8

gear bolt

4 0 to S O

Side bearing cap bolt Differential carrier to axle

case

Companion flange of front shaft and flange yoke connecting nut Center bearing bracket ut

Companion flange

101 to 123

to

propeller

shaft

29 to 36

17 to 2 S

12

to 18

4 to 3 3 2

17

to 24

1 6 to 2 2

12 to 16

4 to 3 3 2

17 to 24

6 0 to 10 0 43 to 72

Oil drain and filler plug

PD l1

PROPELLER SHAFT Oil capacity about

liter US


pt Imp pt

1 0 2Ji

I Y

Adjusting methods Variable numbers

expressed by

100 1

Dummy shaft Drive pinion

Side

mOl

Use

adjusting

fonnula

bearing adjusting

fonnula

T

TI

N

H A

C

0 17S

T2

PD 18

B

0

0

S

D

H

x

0

01

18 2

xO OI

E H

x

001

0 150

F

PROPELLER SHAFT 8i DIFFERENTIALCARRIER

SPECIAL SERVICE TOOlS Tool number

Description

No tool

I

Unit

name

ST063 10000

This tool is used for attaching gear carrier to

ease

mOl

disassembly

Reference

use

page

on

Figure No

in 620

or

or

Fig PD 7

610

assembly

Diff

For

attachment

SE023

2

ST3I 94S000

These tools are used to

adjust

the pinion

620

height

610

Fig PD 16 Fig PD 17

Drive

pinion setting gauge assembly

@

H190 ST31942000

Dummy

SE209

shaft

ST31941000

Height gauge

SE210

3

ST31970000

This tool is used for

Type H 190

to

the

adjust

pinion height

PD 16

di

35 1 38 30

Fig

610

This tool is used with ST3I 94S000

Collar

620

18 1 dia

1 1 06

27 l

4

KV311 00300

620

For driving out oflock pin of pinion shaft

610 Solid

punch

710 S30 4 5

0 177 di 95

Y 65

PD 19

2

56

3 74

Fig

PI

13

PROPELEER SHAFT

GIFFERENTIAl CARRIER

Tool number No

Description

Fur

Reference

use

page

on

Figure

tool name

Unit 5

Drive pinion outer drift

These tools

are

used when

assembling

drive pinion outer

nUll

in

620

race

race

Page

or

No

PD 9

610

ST30611000 Bar

0

l

t

i

ST306130qo

0

350 13 78

i

ti

Wt

UWrflIfl UU

Adapter

0

350 13 78

ST30611oo0

L

Bar

I

1 I

j

e

II

G

ST3062 1000

2 83 dia

J2

L

0

gI

2l

79

3 11

dia

j

Adapter 6

ST309OS000 Drive pinion rear

bearing

inner

race

This assembly

hydranlic

clamps

rear

bearing

inner

race

and

pulls

it out

by

a

press

Before insertion place another drift facing inner

race

and then

620

Fig

610

Page PD IO

PO IO

S30

press fit

puller

lb

45

1 17 dia

35 2 1 386 dia

ST3003Ioo0 Puller

ST30901000

l

Base 7

KV38102SSO Oil seal

For

installing

24 0 94

80g

the front oil seal

filling

tool ST30720000 Drift KV38102SIO Drift

55 5 2 185 dia

PD 20

5

dia

620

Page

PO U

610

Page

PO l3

PROPELLER SHAFT

DIFFERENTIAL

CARRIER

Toollltlltlbcr

Description

No

tuol

8

Unit

nallle

ST3 1530000

This tool is used to hold the

Drive pinion flange wrench

to case

Ilange

mOl

in

the operation of tightening

and lousening drive piniun nut

For

Reference

use

page

on

Figure

or

No

620

Fig

8210

PD 5

Fig

PD Y

610

Fig

PD 28

Fig

PD 19

Fig Fig

PD 12

710 SJO l

54

9

ST3127S000

This toul is used

to

Ilwasure

2

b

13

the preload of piniun

All

bearing

models

Preload gauge GG91030000

Turque 2

wr

CD

nch

L

IIT62940000 Socket adapter

J

O

lJ ct

IIT62900000

1

4

II J

x

3 8 3 8

UJ L

2 1

r

Socket adapter

10

ST3J06S001

This tool is lIsed to

oul side

Jut

bearing

620

Diff side

610

bearing puller

SJO

PD I 5

set

ST3JOSIOOI Diff side

bearing

puller STJ306 I 000

38

1

50 di

Adapter II

ST33230000 Diff side

bearing

Use of this tool makes it

damaging

possible

to drive in

it

bearing

without

620 610

drift

5t

2 0t

di

0ll 1B 1

PD 21

Fig

PD IS

r

SECTION FA

DATSUN PICK UP

FRONT AXLE FRONT

MODEL 620 SERIES

SUSPENSION

FRONT AXLE AND FRONT SUSPENSION

FA 2


FA 13

TROUBLE DIAGNOSES AND

CORRECTIONS SPECIAL SERVICE TOOLS

lNISSAN I NISSAN MOTOR CO TOKYO

LTD JAPAN

FA 14 FA 17

Front

Front Suspension

Axle

FRONT AXLE AND FRONT SUSPENSION CONTENTS GENERAL DESCRIPTION

FRONT

FA 2

REMOVAL

FA 3

AXLE

AND INSTALLATION

INSPECTION

8

FA

9


FA 3

FA

9

ADJUSTMENT

FA 4


FA

9


FA 4

INSPECTION

FA

9

INSPECTION

FA

WHEEL BEARING

TORSION BAR SPRING

FA

5

UPPER AND

FA 8

FjEMOVAL


FA 8

INSPECTION

FA 8

DISASSEMBLY AND ASSEMBLY INSPECTION

SHOCK ABSORBER

FA 8

STABILIZER

LOWER

LINKS

FA 10

AND INSTALLATION

FA l0 FA ll FA ll FA Il

ADJUSTMENT

FA 8

VEHICLE POSTURE

FA ll

INSPECTION

FA 8

WHEEL ALIGNMENT

FA 12

ROD

FA 8

STEERING ANGLE

FA 12

REMOVAL TENSION

AND INSTALLATION

GENERAL DESCRIPTION

uUl

FA224

Fig

FA 2

FA j SectionallJiew of

xle fronta

and fron t suspension

Front Axle

The design of the front suspension double the independent

Front

Suspension

FRONT AXLE

adopts

wishbone type suspension used the torsion bar spring Both the upper and lower links are installed on the bracket which is welded

on

INSTALLATION

the

the frame

1d A swing to allow the knuckle to move freely in a vertical

above links

spindle

REMOVAL AND

Removal

support vehicle

Jack up and

I

dimension

the

stands

the

at

in

frame

on

safe

a

manner

The top and bottom of the knuckle

2

spindle support are connected to the upper link through rubber bushing and to the lower lick through screw bushing The tension rod held by the brack

3

ets on the chassis frame and lower lick

nut from knuckle

wiih

6

rubber

bushings

bears the force

is installed to the

torque

which attaches to the lower link is installed to the

anchor that

The

shock

is

absorber

S

Remove hub cap and then remove pin adjusting cap and spindle

cotter

Remove

spindle

wheel

outer and

hub

wheel bearings

of the

bracket

installing front to sliding parts

8

Remove

knuckle

from

arm

knuckle spindle 9

Remove

double

of the

Furthermore

matters

axle

ring

se

lightly

when

coat grease

the lower end of

on

support In

The

this

select

operation

spindle

shims to obtain the specified clearance between knuckle spindle and knuckle

spindle support ance

bracket Of the frame limits the verti cal motion

reverse

spindle support Install thrust bearing and spindle shim together with knuckle spindle to knuckle spindle

rubber secured to the

bumper

in

by noting the fol

knuckle

the lower lick The

axle

to removal

Insert O

I

king pin lock bolt

bracket is bolted to

insulated

front

The

spring

frame

Install

the flange of knuckle spindle

is attached to the

chassis

Installation

bearing washer

telescopic hydraulic type

The upper stem

lower

Remove brake drum

arm

firmly The both ends of the torsion bar spring are serrated action

cylinder

4

quence lowing

to chassis frame

secures

FA226

Fig FA 3 R moving knuckle piridle

and grease seal from knuckle spindle 7 Remove brake disc assembly from

The front end of the torsion bar

opposite end

connector from wheel

inner

of fore and aft direction

spring

Remove front wheel Re ove brake hose together with

with

a

bottom of spindle

suspension lick

Clear

To measure the

filler gauge

up the

jack

slightly

Standard clearance The knuckle

spindle is connecied

0 1 mOl

to

the k

ufkle spindle arm by the king pin The king pin bushings are fitted to the upper and lower the

knuckle

provided keep

arm

spindle

at the

seals

water and dirt from enteri arm

transmit

ttLe

steering wheel

movement

to the knuckle

The wheel hub is

on

Line

knuckle to

of the

10 move

with

spindle two

the knuckle

Tlie brake drum and wheel

spindle secured to ihe

bearing

Be sure to iristsll thrust

to face coverea side

2

to

spindle

supported by

taper roller bearings

less

upward

are

g

is connected

the lower end of the knuckle to

Note

or

portIOns of

and

portions mentioned

The knuckle

FA225

R mol1ing king pin loch nut

Fig FA

0 004 in

are

hub by the hub bolts

After removing air breather re plug from the top of king pin the

the

plug

M 12 1 2S hole and II

in

413 0

screw

pull

Apply

with

a

a on

tap

bolt into threaded

out the

out

and detach it Take

Be

sure

plug

king pin along

with

knuckie spindle

from

a

spindle

smoothly and

shim if necessary

for

Press

knuckle

plug

soft haJnmer

fit plug

spindle

as

to

Then

sure

to

check

required the upper of install lower

to the lower knuckle

Make

reailjust

In addition

bushings and king pin

Note with

to check killJckle

smooth movement Be certain to move

3

drift to the top ofking

Tap spindle

support

a

Drill

diameter hole

thread hole

pin and drive lower plug 12

method

following

5 mm 10

notch in

locking bolt hole of spindle support with the king pin and secure lock bolt up

spindle

place

lower

plug

conectly

knuckle spindle io drop thrust

care not

4

bearing FA 3

Secure

knuckle

arm

to knuckle

Front Axle

Front

3 to 10 spindle and torque bolt to 12 1 kg m 75 to 88 ft lb Bend lock plate to engaged flats on boll head

bearings proceed

Note

I

When

used lock

disassembled

To attain proper

Suspension

preload on wheel following opera

the

tions

discard

kg

plate

Torque spindle 22 to

m

25

nut to

ft lb

3 0 to 3 S

using torque

wrench 5

Pack

lower

until grease

the

to

grea

bushings

on

c omes

r and upP

knuckle

spindle

from

out

grease

seal 6

fA22S

Fill

wheel

up to

grease

and

hub

with

cap

Fig FA 6 Meauring bearing rotation

the described level See

atarting torque

4 Figure F A

S FA227

Fig FA

5

Tightening apindle nut

Install

a new

cotter

pin

Bend the

ends of coller pin around the castel lated flange of adjusting cap Then install hub cap

2 FA141

Gre ing wheel hub

Fig FA 4

Rotate

clockwise

wheel and

bearings

seat

hub

few turns

a

counterclockwise

to

Then retighten spindle

nut to the same

tightening torque

Be

certain to rotate hub

7

Pack roller and

assembly

cone

and the cavity of grease seal lip with grease 8 Coat

knuckle spindle

bearing

thread washer

of and

Secure wheel hub

bearings

bear

ing washer and spindle nut on knuckle spindle and adju t bearing preload Wheel referring to the paragraph

bearing adjustment Note

the castellation cotter 4

spindle

If

Spring balance indication

bearings for the of rpose pu ving their long life care to taking keep wheel be8rlngs seal grease bearing washer and spin dle nut clean when installing them

New

If hub

bearing

measure

starting torque torque is deviated from the value r place beari gs r re The starting torque can sured by a spring balance as Figure F A 6

wheel

on

in the

properly


Knuckle spindle

the cap with the

tion

Be sure to obtain correct pre

load

pin hole

on

Check the hub rotation

rotates

lock nul

bearing 9

the

to

grease

smoothly 3 Back off spindle nut in range from 40 to 70 degrees Locate adjust ing cap on spindle nut so as to align

rota

measured

specified dju st be

mea

shown in

I Drive spindle bushing and grease seal out of knuckle spindle with KiTlg Pin Bush Drift ST3S380000 Discard

bushing

and grease

seal

when

disas

sembled 2

After

cleaning king pin bores thoroughly install bushing carefully by using the above special tpol Posi tion bushing in accordance With the instructions fIlled in Figure FA 7 and

at hub bolt

8 FA

bearing 2 1 kg 4

Ib

o

ess

Used bearing 10 kg 2 2 lb

or

34 34 1

less

Upper side

mm

in

lower boss

in

I I

Notes a

WHEEL BEARING D

TM

ing on

causes

connected between hub boll and

the

abnonnal

bearings

II

gential direction against normal line

NT

Wrong adjustment

1

When measuring the starting force pull the spring balance toward tan

of wheel bear wear

and

and knuckle

score

spindle

b

spindle center Axial play is permissible 1 0

mm

0 004 in

4 FA

or

less

to exist in

I

Pla ce

this position

grease

nipple

Upper side in upper boss

in line with

hole FA229

Fig FA 7 King pin bu hing

Front

Front Axle

Suspension

Wheel hub Level line 1

INSPECTION

removing grease seal with

After

lightly tap

screwdriver

outer race

King pin and bushing and replace king pin andlor tne following faulty condi if bushing

cir

Check

with a hammer by ap brass bar and remove outer

cumference

plying bearing

a

outer race 2

Remove

from

Level line FA230

Fig FA 8 Bushing location

Remove

nipple and drill grease hole on bushing through thread ed grease nipple hole When grease hole is drilled remove metal chip and burr thoroughly grease

tion is detected

When

all

between

of old grease

traces

and

hub

bearings

partial meter

knuckle

Note

When

grease

king pin and bushing in dia exceeding limit listed

below

3

Install

and

inner

in hub with

outer

bearing

properly

seat the races

to

4

Pack the inside of hub and hub

cap

with

grease to

0 15

in hub

sure

specified

Clearance limit

suitable tool Be

a

Standard dimensions

the de

King pin

outer

same

When

118 0

mOl

nipple hole it into

pressing nipple

lubricant

Bushing

inner diameter 20 010 to 20 035

in

it

has

a

hole

ThorougWy clean grease and dirt from wheel bearing with cleaning sol vent

with

of moisture

that

in

see

Pin Bush

Reamer HT56802000

Place inner

ler assembly

mOl

ly

reaming from both lower bushings When

out

upper and

check outer

Fig FA 10 Greasing bearing cone and roller assembly

freely and pit ing or

crack

for condition

race

moval of outer

is free from wear

race

Also Re

from drum is not

necessary

0 7878 to 0 7888 in

Carry

FA009

5

20 010 to 20 03S

that it rolls

noise

diameter

when fitted

Note

and dry with compressed air free Check wheel bearing to

position align

value with King

Bushing inner

Wheel bearing

2

ad

an

Ream the inside of bushing to the

specified

mOl

in

spindle bushing 4

mm

0 7866 to 0 7874 in

ditional hole need not be drilled

grease

diameter

19 979 to 20 000

scribed level See Figure FAA Also pack the bearing cone and roller as semblies with the

0 00S9 in

mOl

0 7878 to 0 7888 in

spindle bushing

a

scores

direction

Drilling diameter approximate 3

deformation

and excessive clearance

wear

spindle races

3

from hub

tapping circumference tap evenly

race

to the

seat it

bearing

cone

in hub Coat grease

lips of

new

Shown

and rol

slight

grease seal

below

is

the

cha rt which

furnishes the necessary information on Visual Serviceability Standard for

and

Wheel Bearing

properly

reaming upper side use lower side as reaming guide and when reaming lower side

ing guide correctly 5

use

upper side as ream

King

ST35390000 take

care

serviceability standard for wheel bearing

@

Press fit grease seal

with

Visual

align the center line

to

Pin

on

Grease

upper Seal Drift

@

installing grease seal damage seal lip

In

not to

J

arm

@ 1

Outer

race

2 Roller

@

@

35390000 51

3 Small collar 4 Inner

race

fitted surface

5 Collar surface 6 Inner race surface

A

@

7 Outer

race

8 Outer

race

9

2 CD

Q

jJ @

Roller

10 Inner

tilted surface

rolling

lcc surf

surface

race

11

Large collar 12 Supporter FADD6

FA231

Fig FA 11

Fig FA 9 Installing grease seal

FA 5

Wheel bearing assembly

Front Axle

Judgement

X

Unserviceable

6

May be

Suspension

Front

used when minor

Rust should be removed with

0 emery paper

Race and roller

C

2 e

0 0

Flaking

Cause

E

Components

u

0 0 0 CIl

X

Service life due

to

rolling fatigue However this symptom

the service life The

following

causes

are

occu

before

considered

Abnormal load overload

Fig

a

b

Crack

Improper handling X

X

X

installing

or

Excessive tightening Excessive gap and

a

considerable shock received from the outside

Rapid heat generation

on

the

race

due to creep

Bitten supporter with seizing rollers Abnormal thrust load

Fig

c

d

Seizure

Tapped X

X

X

n

with

the most

a

hammer while removing

cases

seizure occurs as the result of grown

discoloring

or

flaking Scratch

6

6

6

Shock is

given carelessly during

installation

Bit foreign matter

Recess

or wear

6

6

6

made by pressing

removal

or

other

rough handling

scar

due to

striking

striking Fig e f g

or

Wear

Careless installation

Recess made by foreign matter

6

6

6

Poor lubricant

quality or deteriorated

lubricant

Intrusion of dust Fitted surface is worn remarkably

Wear due

to

preliminary

excessive

preliminary

pressure

Biting

6

6

6

Excessive

Fretting

6

6

6

The fitted part is discolored to brown

Fretting

corrosion

rust

metal contact surface

FA 6

pressure or

on

faulty

lubrication

or

fitted part

black means

fine relative

slip

on

Front Axle

Front

Suspension

Race and roller u u

Cause

e

Components

2

2

0

3 0

t

c

Rust

6

6

6

Temperature

increased during operation lowers when the

moisture inside the

stops

bearing

is condensed

bearing

becoming fine drips

and the grease is moistened The

bearing

has been placed in

a

highly

moistened place for

a

long

period of time Intrusion of moisture h

Fig

bare hand and

The wheel bearing is

Discoloring

chemicals etc or the bearing is touched with rustproof action has been taken

Slight discoloring may become

serv

iceable if discoloring

no

can

In the

most cases

be removed with solvent

like oxidized oil stain due to grease

this occurs when preliminary pressure is too high

by polishing

or

I

I

n

I

v 1

dJ

i

f Inner

a

race

b

flaking

RoUer flaking

c

Cracked inner

race

t c

fJ v

d

Cracked roller

iT t

1 1

t 11

I

1

tt

e

Recess

Jt l

inner

race

Rust outer

race

on

f Recess on

outer

race

t

F 1ll

j

JJ

J I

t

l

1

ollf

c

oe

g

Recess

on

foDer

h

F

A007

Fig FA 12 Defective conditions of bearing

FA 7

Front Axle

Specifications for

SHOCK ABSORBER

Raise vehicle

2

Remove wheel

on a

All models

hoist

or

Piston stroke

stands

3 m sec 0

rubber bushing Remove bolt from the lower end

110 4 3

in

mm

kg lb

Damping force

the upper stem of shock absorber and remove outs washer and

4

shock absorber

Item

Hold

3

Suspension

Model

REMOVAL AND INSTAUATION 1

Front

0 98 ft sec

j

Rebound

76

168

Compression

38 84

of shock absorber

and rubber bushings for crack wear and deterioration Replace if ne

STABILIZER

cessary


FA232

FA 13 Shock absorber

Fig

I

Raise vehicle

2

Remove wheel

3

Loosen secUring nut at the lower

a

on

hoist

or

stands

link side of stabilizer Remove bolt securing stabilizer mounting bracket to chassis frame 4 Retain

S

lower rubber bushing in

position install the lower end of shock absorber to the bracket of lower link and torque the bolt to 3 1 to 4 1 kg 23 to 30 ft lb Note

m

Insert the bolt from the front

side of vehicle

Install the upper end of shock absorber to body bracket and tighten Jt n

to the

specifjcations

Tightening torque 1 6 to 2 2 kg m 121016

reverse se


quence to removal noting the follow ing instructions

I

Raise vehicle

S

2

Remove wheel

3

Remove

Attach stabilizer mounting brack tightening bolt to

et to chassis frame

16

6

lock

Install stabilizer in the

TENSION POD

to

2 2

kg

12

m

to

16

ft lb

6

Install stabilizer lower link side to

connecting rod and tighten

specifications

as

shown

nut to the

in

a

CD

hoist

stands

from both ends

Remove bracket bolt

@

from the

front end of tension rod and

remove

tension rod with bracket

Figure

FA 14

Then torque lock nut toJ 6 to 2 2 kg m 12 to 16 ft lb

ft lb

or

of tension rod 4

torque

nuts

on

CD @

INSPECTION I

Check shock absorber for visible

defects

oil

and

leaks

Place

shock

absorber vertically in a vise and hand stroke shock absorber as outlined be

f A234

low

Fig FA 15 Ten ion rod

Extend sorber

long

as

as

and compress shock

faI

as

possible

travelling

ab

not present in

hydraulic resistance is bqth Iirection replace

absorber

or

Replace

A233

Fig FA 14 Stabilizer detail

possible

If smooth

2

F

as

Install tension rod in

INSPECTION

qunce to removal

rubber bushing if crack

deterioration is detected

Check

stabilizer

FA S

for deformation

instructions

reverse

noting the

00

following

Front Axle s

Install

tighten

nut

tension to

rod at

rear

end

4

make the distance of

kg

12 to 16 ft lb

m

6

Install

bracket

Anchor arm

rear

and detach

spring

S

Withdraw torsion bar

after

pulling

spring

to

A

0 98 in distance

Temporary tightening

rear

anchor

ou t

setting post ion

ISt02Smm

59 0

ring

to

the

at

cover

snap

ward rod

tension

dust

Remove

end of torsion bar

rubber bushing to be 4 mm 1 315 33 in and torque lock nut to 1 6 to 2 2

Suspension

Front

B

60 to 70 mOl

arm

36 2

realWard

to 2 76 in

chassis frame bracket and torque nut to 1 6 to 2 2

kg

m

to 16 ft lb

12

Installalation

When two rubber ferent

bushings are dif arrange adjusting nut

in size

Standard dimension is 11 0 in as shown in

lock

Figure

to 1 6 to 2 2

nut

kg

433 0

mOl

FA 16

the

Torque to

12

m

Install reverse

I

16

Il 0

11 0

spring

in the

of removal

noting

bar

the serrations of

on

spring and

torque

arm

Note

Be sure to install

install it

to

torsion bar can

L

Left

marked

R

Right

on

the end

Adjusting

4W Fig FA 18 Setting procedure

Notes

011 0

0 433

Install

anchor

adjusting

nut

sion

See

Figure

arm

is

nut

arm

obtain

to

FA 17

and

tighten

A

dimen

upper link should be in

contact with rebound

bumper

rubber

b

See

Figure FA 18 Install snap ring and dust cover Temporarily tighten adjust B ing nut until specification is

w

reached

mm

adjustment height

are

found

under

Adjustment

on

Discard

Install

ring

to

4

I

kg

page FA II

old snap ring moving it Replace with during reinstallation wheel

full fuel tank

Fig FA 16 Tension rod detail

after

re

new

one

and lower vehicle

no

at curb

passengers

refer

Adjustment

Torque lock

nut

to

3 1

to

1 4

22 to 30 ft lb

m

INSPECTION

Check tension rod for bend and

faulty condition Repair or replace as required 2 Check bushing rubber for wear and deterioration Replace if neces

I Check torsion bar spring for wear twist etc When adjusting vehicle

the thread for

replace

posture FA236

Fig FA 17 Installing anchor

arm

with

a

new one

can not

torsion

if the

bar

TORSION BAR SPRING

Specifications for

torsion bar

be obtained

spring

REMOVAL AND

All models

INSTALLATION Removal 1

Raise vehicle

2

Remove wheel

3

Loosen

on a

at

hoist

Diameter or

spring

stands

anchor

x

length

mOl

in

Torsional rigidity

kg

m

219

x

830

0 862

3 74 27 I

deg

FA 9

ft lb deg

spring

specified height

sary

bolt

weight

I

INSPECTION

nuts

are

the final

performing

Adjust vehicle posture

in FA235

I

specifications

preliminary rough settings that determines the ride

3

36 6 l 441

the

directions for

A

to

8

and

only

When anchor

properly adjusted

specification i Y

Unit

A

3

2

I

1

bumper

j

right and left springs correctly They

be identified with

and

4 1 33 315

433 0

Rebound

rubber

433 0

surface

11 0

UjP je

instructions

Coat grease

lP

t

bar

sequence

following

torsion

ft lb

torsion

x

32 68

FrClnt Axle

Front

Suspension 4

UPPER AND LOWER LINKS

link

Install upper link spindle to upper mounting bracket with used

camber

adjusting

Torque bolt REMOVAL AND

to 6S ft lb

INSTALLATION

S

Removal I

Raise vehicle

2 an

6

hoist

on a

or

stands FA238

Remove wheel and brake drum as

Fig

assembly

3

Remove wheel hub Refer to

FA 20 Removing upper link

spindle

see

4

Loosen bolts retaining brake disc

to knuckle

spindle

and

remove

brake

12

Remove knuckle

5

spimgJ stabilizer

arm

torsion bar

shock absorber

tension rod in t ili order

and

referring the

related sections Remove upper

6

curing

knuckle

fulcrum bolt

spindle support

se

to

upper link assembly and disassemble them

retaining lower link

Remove nut

spindle and

disc

SI

to the lower end

seat

spindle support

Coat

grease on the thread of fulcrum pin and line up the notch of fulcrum pin with knuckle spindle sup port for inserting cotter pin Fit fulcrum pin to spindle support with a soft hammer Secure cotter pin and torque lock nut to 0 8 to 1 kg m

Front Axle

tion

to 7 0 to 9 0 kg m

Install dust

of j nuckle

shims and bolts

remove

lower link

spindle

Remove lower link with torque from mounting bracket

Using Transverse Replacer ST36070000

Unk

13

bushing drive

it

tap

out

with

lower

link

to a

arm

of

Coat grease to the tIuead portion screw

bushing inside liberally Posi

tion knuckle

Bushing

lower link

hammer and from

bushing

S 8 to 8 0 ft lb 7

bracket

at the

spindle support

center of lower link and secure screw

bushings temporarily by the

ascertaining correct

hand

shown in Figure

as

Mter

dimensions become

torque screw bushings kg m I4S to 217 ft lb

FA 22

20 to 30

to

Remove upper link bushings from

7

knuckle 8

spindle support

Remove

screw

bushings

from

both ends of lower link fulcrum pin 9

Loosen nut at lower portion of

knuckle

spindle support

and

out cotter

pull

crum

from inside

pin retaining ful

pin

3

Pull out fulcrum pin with drift and remove knuckle spindle support 10

with knuckle

spindle

Then detach dust

from lower link

F

cover

Fig

FA 21

A239

Removing lower link bushing

9 05 to 11 05 0 3563 to 0 4350

36 5 1 431

9 05 to 1105 0 3563 to 0 4350 FA240

Fig

FA 22 In tailing

IICrew

bu

hing

InstallatIon Install upper and lower links in the

sequence to removal the following instructions reverse

I

link

noting

When the collar inside of lower

mounting bracket and bushing

outside

are

rusted

remove

rust with

emery paper FA237

Fig FA 19 Removing fulcrum pin

2

Fit lower link

link mounting verse

Link

bushing

into lower

8

comes

filler 9

plug

with grease

out from dust cover

plug Upon

installation

make

grease

Reinstall

sure

that with

smoothly

Operating torque Less than

Replacer

5 kg 0

m

3 6 ft lb

ST36070000 with II

link

Remove

spindle

bolts

and

retaining

remove

upper

upper link

a

10

Install

drift squarely

knuckle

3

II

Secure lower link to lower link

bushing

spindle with camber adjusting shims

torque

from

S8 ft Ib

body bracket

When tapping the frift hammer be careful to hit the

filler

fulcrum pin operates the following torque

bracket using Trans

Bushing

Replace

nipple and pack grease until

with lower link spindle and nut to 74 to 8 0

kg m

54 to

to

upper link

torque 38 ft lb

14

1n

upper

link bushing

to

spindle support Install knuckle spindle support insert fulcrum bolt and

nut to 3 9 to

3 S

kg

m

28

to

Front Axle Note

When

fulcrum pin

installing

4

insert it from rearward of vehicle

12

Install

sorber and

tension

stabilizer I

knuckle

rod

shock

torsion bar

arm

ab

to

Install

brake

disc

to

out from dust cover Reinstall f1ller plug

14

When

screw

of upper link

spindle fulcrum pin and screw bush ing and repair or replace if necessary Note

Discard dust

cover

and dust seal

when disassembled

installing

torque

tighten

it to the

lower link

arm

on

following

specifications

as

and

torque knuckle spin dle nut to 8 0 to 9 0 kg m 58 to 65 assembly

the

Lower link

to 4 2

Install wheel and brake drum

an

Check

the

knuckle

spindle and torque securing bolt to 5 0 kg m 30 to 36 ft Ib

to operate upper link

sure

comes

spring

referring

Suspension

spindle smoothly after installation 5 Replace filler plug with grease nipple and pack grease until grease

related paragraphs 13

Make

Front

Serration boss

VEHICLE POSTURE

1 8 to 2 6

ft Ib

ADJUSTMENT

kg

m

Vehicle posture may be incorrect

13 to 19 ft Ib

due to weakened

Arm head 2 7 to 3 7

20

to

kg

condition

m

27 ft tb

are

spring or other faulty following procedures when adjustment is Ie

The

necessary

quired That is

the vehicle posture can be adjusted by obtaining only the speci

INSPECTION

DISASSEMBLY AND

Upper link spindle fulcrum pin screw bushing

I

2

ing

I

mm

in

spindle

from

Apply screw bushing to upper link spindle or fulcrum pin and measure

clamp

dust

axial end

and dust seal Secure upper link

When

Detach upper link

cover a

and remove

vise and loosen screw

bushing

link

spindle

sequence to disassembling following instructions 2

Torque

mm

ft Ib

to

Install

cover

and

reverse

noting

the

bushing on upper kg m 253 to 398

new

dust seal and dust

secure

them with

screw

between them

the end play exceeds

or

35 0

in

replace upper link fulcrum pin together with

bushings

H

on

stands

dimension with turn

Adjust adjusting

nut

anchor bolt

H

dimension changes approximately 0 J38 in

nut is turned one

complete

turn

To make the best vehicle

3 H

5 3

vertically when adjust posture

dimension must be in the follow

ing range

the

55

screw

link to 3S

in

play

0 0138

spindle Assemble

changing

Raise front of vehicle

and

links

dimension

length of anchor bolt

Upper link

upper

H

fied

ASSEMBLY

H dimension

in

All models

Condition

clamp

mOl

3

Coat grease to screw bushing in side and the thread portion of upper link spindle liberally Screw front and rear same

fied

links

to

length

figures

Vehicle empty no payload

upper link spindle in the to obtain the speci

79 to 84 3 11 to

Vehicle loaded

5 2 15 54

so as as

31 3

shown in Figure FA 23

Notes a

i o

Vehicle empty no payload consists of the following conditions I

Full tank of

gasoline

radiator

f1lled and engine oil level full 2 Spare tire wheel jack and jack handle in

design position

b Vehicle loaded consists of the fol Unit

mm

in I

44 6 1 FA2 1 56 Fig FA 23 Upper link and upper link

spindle

lowing

conditions FA242

For all models

leg I

103lb

2 persons and SIlO

payload FA

Fig

FA 24

Dimension for standard vehicle postl4re

Front Axle

Front

Suspension When

WHEEL ALIGNMENT Correct

side

wheel

front

attains proper vehicle

alignment handling charac

Before

After correct

sure

toe in is to 8 0 to

nut

rJ

to carry out

a pre of the front end

1 Tire pressure and balance

r HI

CD

r

cCJ ter

Steering gear play 4 Steering gear housing at frame S Steering linkage and connections 6 Shock absorber action

Do not front

f

b

equip inspection

c

inst c tions furnished with the

should be made with the vehicle level

make difference between

and

FA244

shims in thickness

rear

beyond 2 mm 0 079 link spindle

When using the equipment for front wheel alignment inspection follow the the

in

on a

Fig FA 26 Adju6ting toe in

upper

STEERING ANGLE

Umit shim thickness for anyone stack within 6 Do not more

use

nun

0 236 in

Check steering angle and

shims for anyone stack

the 2 sheets

Loosen lock nut at stopper bolt and

Measure toe in and adjust if neces

Camber and caster and

caster

and

adjust them in accordance with the following procedures if necessary camber and caster

ad

are

justed by increasing and decreasing thickness of adjust shim inserted be link spindle and upper link mounting bracket upper

To

adjust

caster make

a

difference

between thickness of front and shims By in

adding

front

at

creased

by

a

side 33

shim I

mm

At

the

To adjust camber add rear

mOl

amount

sides

in

a

in

2 mOl

by

steering wheel

straight

to

ing gear straight ahead position Loosen lock nuts thread

and

and turn Turn

cross

shown

by

ID

cross

@ left

hand

right hand thread

rod

CD

adjust

to

toe in

rod to forward direction

arrow

as

FA245

and toe in is reduced

Fig FA 27 Adjusting steering angle

6 S

or remove

an

Item

Model

I

mOl

by 13

0 079 in and 4

mOl

0 039

in

1

All models 2 to 3

0 079 to

118 0

Toe in

degree

thick at both sides

mm

in thickness

Turn

ahead position with front wheels in the same position Then check steer

time

same

available in I

are

follOWIng procedures

0 039

pack of shims

camber will be decreased

Shims

the

carry out

of shims to front and

By adding

0 039

rear

For adjustment

sary

caster will be de

camber will also be decreased

equal

the

adjust steering angle with stopper bolt Mter obtaining correct steering angle secure lock nut firmly

Toe in

tween

use

follow ng procedures if necessary

and at curb weight

camber

0

Notes a

Furthennore

I

e

Fig FA 25 Adjustingcamberand

3

Both

m

FA243

2 Wheel bearings and nuts

Measure

kg

S8 to 72 ft Ib

liminary inspection parts for the following conditions

ment

obtained 10 0

front wheel align

adjusting

make

rod is turned to opposite

in is increased

tighten lock

teristics and the least steering effort with a minimum amount of tire wear

ment

cross

toe

2

10 to 16

Camber

lOIS

Io

Caster

10SO

4S

157 0

Kingpin

incIinal10n

Steering angle

60IS

I

Innerwheel

10 360

I

Outer wheel

10 310

1

The extreme front and rear of the tire center

2

The total

FA 12

angle

of the both tires

Unladen

Front Axle

Front

Suspension

SERVICE DATA AND SPECIFICATIONS King pin Clearance limit between the king pin and

bushing inner diameter when fitted

Bushing

0 15

in

mm

0 0059

20 010 to 20 035

in mm

0 7878 to 0 7888

Clearance between the knuckle spindle

support and spindle

mm

less than 0 1

in

0 004

Wheel bearing

kg

Tightening torque

m

ft Ib

22 to 2S

40 to 700

Spindle nut returning angle Wheel bearing rotation starting torque When both bearing and seal are new When

3 0 to 3 S

readjusted

kg kg

em

in Ib

em in lb

less than IS 13 0 less than 7

6 1

At the hub bolt

bearing and seal are readjusted

When both When

Suspension

new

less than 2 1

kg lb kg lb

4 6

less than 10 2 2

link

Upper link sliding resistance

kg

m

ft Ib

less than O S

3 6

Lower link

kg

m

ft lb

less than O S

3 6

sliding resistance

lightening torque

kg

ft Ib

m

Brake hose connecting nut

19 to 2 S

14 to 18

Wheel bearing lock nu t

3 0 to 3 5

22 to 2S

Brake disc fIXing bolt

4 2 to S O

30 to 36

3 to 12 1 10

Knuckle arm fixing bolt

2 1 to 2 S

King pin lock bolt Torque

IS

74 to 88 to 18

arm

Arm end

2 7 to 3 7

20 to 27

Serration boss

18 to 2 6

13 to 19

74 to 8 0

S4 to 58

Lower link

spindle

Upper link

screw

nut

24 to 35

bushing

Upper link spindle bolt fIXing

174

to 2S3

7 to 9 51 to 6S

to bracket

Cotter pin lock nut

0 8 to l 5 8 to 8 0

Lower link

25 to 32

screw

bushing

3 9 to

Fulcrum bolt

181

to

231

3 28 to 38 S

Tension rod Lock nut

16 to 2 2 12 to 16

Bracket bolt

1 6 to 2 2

12 to 16

1 6 to 2 2

12 to 16

3 1 to 4 1

22 to 30

Shock absorber Lock nut of the upper end Lower end Stabilizer 16 to 2 2 12 to 16

Bracket bolt

3 1 to 4 1

Lock nut of the anchor bolt

22 to 30

0 8 to l 5 8 to 8 0

Bumper rubber bolt FA 13

Front Axle

Suspension

Front


Condition

Vibration shock and shimmy

Too much backlash of steering gear

Vibration

of each part of

ing of steering wheeL

wheels

traveJling

over

When

is Very much noticeable when

bad roads and at higher

the front wheels the

roads

bumpy

transmitted to the

in many cases

are

speeds

travelling

are

noticeable when travelling

sion

over

of the steering linkage is

play

transmitted to the steering wheel This is

Shimmy

wear

and vibration of front

linkage

steering wheel This

Shock

Corrective action

cause

especially

road

rough

Abnormal vibrations of the front suspen group and the whole steering linkage which when a

occur

Improper

is attained

specific speed

Adjust

air pressure of tire

Correct the unbalance

Unbalance and deformation ofroadwheel

place Unevenly

worn tire

or

Improperly adjusted

Replace

insufficient tightening

or

worn

front wheel bearing

or

loose suspension link

Damaged idler

screw

Replace

bushing

Replace

arm

Insufficiently tightened steering Worn steering

replace

Adjust

Faulty wheel alignment Worn

Adjust

tighten

or

or

TIghten

housing

gear

ball joint

Replace

linkage insufficient back

Improper steering gear adjustment

Adjust

lash

Faulty shock absorber

or loose

Replace

installation

pulls to right or

left

tighten

Adjust

Unbalanced vehicle posture

Vehicle

or

When driving with hands off the steering wheel on a fiat road the vehicle gently swerves to right or left Note

A faulty

rear

of this condition

chapter dealing

and

with the

therefore rear

see

cause

also the

suspension

air pressure of tire or insufficient

Improper of wheel

also be the

suspension may

tightening

Adjust

or

Difference in height of right and left tire treads Incorrect

adjustment

or

abrasion of front wheel

Replace

Adjust

tires

or

bearing Weakened standard

tighten

nuts

front

torsion

spring

or

deviation from

Replace

specification Readjust

Improper wheel alignment Worn or loose suspension link

screw

FA 14

bushing

Replace

replace

or re

Front Axle

Condition

Vehicle puBes to

Front

Probable

right

or

left

Deformed of steering

Suspension

Corrective action

cause

and suspension link

linkage

Unbalanced vehicle level

Instability of vehicle

Worn

or

Correct the unbalance


Improper

Adjust


screw

bushing

Replace

Incorrect wheel alignment Worn

Adjust

deformed steering

or

Replace

linkage

and suspension

Replace

link Incorrect

adjustment

of steering gear

Adjust

Deformed unbalanced wheel

Stiff steeirng wheel

Correct or replace

Check and correct in the following Jack up front wheels

manner

detach the steering gear and

operate the steering wheel and a

If it is light check steering linkage and suspension groups

b If it

is

heavy

check

and

steering gear

steering

column groups

Improper


Adjust

Insufficient lubricants or mixing impurities in steering

Replenish

linkage or excessively

the part

worn

steering linkage

Insufficient lubricant in gear box

contaminated

or

Add

or

grease

replace

or

replace

gear oil

lubricant Unsmooth

king pin

damaged part

Or

insufficient

Replace

lubrication Worn

or

incorrectly adjusted

wheel bearing

Replace

Worn damaged steering gear and bearing

Replace

Incorrectly adjusted steering gear

Adjust

Deformed steering linkage

Replace

Incorrect wheel

Adjust

Interference

alignment

of steering column

with

turn

signal

or

adjust

Adjust

switch

Excessive steering wheel

Incorrectly adjusted steering gear

Adjust

play

Worn steering linkage idler

Replace

Improperly

fitted of gear box

Incorrectly adjusted Worn

Noise

or

Retighten

wheel bearing


Improper

screw

Adjust bushing


Insufficient link

arm

screw

lubricating oil and grease for suspension bushing and steering linkage or their

breakage

FA 15

Replace Adjust Replenish lubricating or replace

grease

oil and

Front Axle

Front

Probable

Condition

Loose

Noise

Suspension

Corrective action

cause

steering gear bolts

linkage and suspension

Retighten

groups

Faulty

shock absorber

Replace

wheel bearing

Replace

Damaged

Grating tire

tire

or

partially

Replace

Worn ofloose suspension link

Replace

Improper

noise

Jumping of disc wheeL

Excessively

Worn steering linkage and steering gear

bushing

Adjust

air pressure of lire

Incorrect wheel alignment

Adjust

Deformed knuckle spindle and suspension linkage

Replace

Rough driving

Avoid rough driving

Improper

worn

screw

Adjust


Unbalanced wheels

Adjust

Faulty shock absorber

Replace

Worn tire

Replace

Deformed wheel rim

Replace

Improper


Adjust

Adjust

Incorrect wheel alignment

Damaged

wheel bearing

Incorrect brake

Improper

tire

Replace

Adjust

adjustment

shifting

rotation

Rough and improper wiving

FA 16

manner

Adjust Drive

more

gently

Front Axle

Front

Suspension

SPECIAL SERVICE TOOL Tool number

Description

No tool name

Unit

mOl

For

Reference

use

page or

on

Figure No

in

ST35380000 22 2 dia 0 874

King pin bush

This tool is used to drive out

drift

king pin bushing

FA 4

620

Page

620

Page FA S

SE234

2

HTS6802000

King pin bush

This tool is used to correct

reamer

king pin bushing

FA 17

SECTION RA

REAR AXLE REAR



LTD JAPAN

SUSPENSION

REAR AXlE AND REAR SUSPENSION

RA

2


RA

7


RA

8


RA 9

Rear Axle

Suspension

Rear

REAR AXLE AND REAR SUSPENSION CONTENTS RA 3

DESCRIPTION REMOVAL AND INSTALLATION Rear axle

RA 3 RA 3

assembly

Rear axle shaft and wheel

spring

RA 6 fJ RA

Rear axle shaft and wheel

4 RA

bearing

Rear axle case Rear

Shock absorber tNSPECTION

Rear axle

RA 6

bearing

RA6

case

RA 5

Rear

RA 5

Shock absorber

fJ RA

spring

fJ RA

4

J I

i I

LJ

o 1 1

Air

2 3

Thrust block Nut T

@ RA132

breather

14

Wheel

15

Rear

bearing

axle bearing grease seat

Supply

3 1 to 4 1 kg m 22 to 30 ft lb

oil

wheel

bearing

16

Rear axle

Shock absorber mounting rubber bush

17

Rear axle shaft

18

Grease catcher

5

Rear spring clip V bolt Rear axle oil seal spacer Rear axle shaft oil seal

19

Bearing

20

Rear axle

21

Nut

7

Supply 8

wheel

bearing grease oil seal lip when assembly Rear axle bearing lock nut T 15 to 20 kg m 10810

9 10 11

T

to

145 ft b

12 13

Road wheel nut T

58

to

grease to

Oil capacity 1

30

cage bolt case

end

case

m

43 to 72 ft4b

bearing spacer

US qt

about 10 7 8 Imp qt

Drain plug T 6to 10kg

shim

m

31 5 4 to

6 4 kg m 391046 ft lb

Nut 5 to 13 0 kg 11

T

m

Rear spring pad Rear spring

32

23

33

Rear

24

Nut

34

Rear spring shackle Nut

22

T 25

7 3 to 9 9 kg m 53 to 72 ft4b

35

1610 2 2kg m 12 to 16 fHb

36

T

Nut T

liter

43 to 72 fHb

m

26

Shock absorber rubber bush

65 fl Ib

27

Shock absorber

8t09kg

Filler ptug T 6toIOkg

83 to 94 fHb Rear spring rear bush

Rear axle bearing lock washer Plain washer Rear axle bearing cage Road wheel bolt

Rear axle

29

seal lip when assembly

4

6

28

spring

1 15 to

13 0 kg 83 to 94 fHb

m

37

Rear spring Rear spring front bush

38

Rear spring front pin

T

Fig RA 2

Tightening torque RA I Crou uctional view of rear a xl

and

uapension

Rear Axle

DESCRIPTION The

axle

rear

2 is of the

assembly

semi

floating type in which the vehicle weight is carried on the axle shafts through bearings enclosed in the bear ing

cages

axle

is

case

axle case

outer rear

on

pressed steeJ

a

The

Banjo

type housing The rear axle assembly is attached to the frame through semi elliptic leaf and

springs

absorbers end

telescopic hydraulic shock Rubber

of the

absorbers

bushings

leaf springs

across

propeller

three

clamps ID

and connector

nect

combination is restored

removing three clamps ID

assembly 3 Remove bolts retaining center bearing bracket and connecting shaft to companion flange Withdraw pro peller shaft sleeve yoke from transmis sion

by moving

passing 4

shaft rearward

it under rear axle

Disconnect

Q

the

at

rear

hand brake cable

by removing adjusting

@

nut

and shock

@

Slide front cable rearward and discon

5

cable

rear

@

ID by

at connector

Disconnect

frame

rear brake hose at Cover brake hose and pipe

@

openings

to

prevent entrance of dirt Disconnect shock absorbers at lower end f and push shock ab 6

sorbers up out of the way 7 Lower jack under axle

case

U bolts

spring clips separate axle case from spring move

@

Re to

to absorb vibra

designed

are

relationship

Suspension

shaft flange and companion flange of differential carrier so that the original

either

at

Mark

Rear

tion and noise

The rear axle shaft splines engage the differential side gears with a float ing fit The outer ends are supported in the

bearing bearings The

cages

bearings

by tapered roller lubricated

are

by

wheel bearing grease The axle shaft oil seals are located outboard and inboard of the

bearing The bearings

are

se

cured against shoulders on the shafts by press fit and held in place by a

large

nuts

The bearing cages hold the

against shoulders Whee

side

on

the axle

thrust

bearings

case

is taken at

the

wheel

bearings

block

so

moved

simply by removing the bolts

holding

the

through

axle shaft may be

an

the brake disc to the

cage and the

thrust

rear

axle

re

bearing

case RA312

Fig RA 2 Under view 8

jack under center of axle case through space above spring and take it out to the


Place

case

Pass

a

axle

Tightening torque U bolt

side

53 to 72 ft lb

REAR AXLE ASSEMBLY It reaT

Shock absorber lower end nut

is not

necessary to remove the axle assembly for any normal

1 6 to 2 2

the

aged

removed

if the axle

case

Raise

to

IS

starts to raise rear axle

Place members wheels

stands on

just

Fig RA 3 Removing

rear

rear

kg

m

the

Install the axle reverse

case

assembly

order of removal

RA 3

in

2 7

kg m

Center bearing bracket fixin

9

to

14 to 20 ft Ib

axle

assembly

solidly under frame Remove

20

RA134

assembly

both sides

18

Propeller shaft to companion flange connecting bolt

rear

center of axle case so it

to

II to 13 ft Ib

of vehicle high enough working underneath Place a

permi t jack under

m

Brake pipe flare nut

is dam

axle assembly may be and installed using the fol rear

lowing procedures I

kg

12to 16ft Ib

repairs However

Spring clip kg m

3 to 9 9 7

holt 1 6 to 22

12

kg

m

to 16 ft Ib

Rear Axle 8

REAR AXLE SHAFT AND

Raise

of vehicle and support case on stands Remove

Unbend lock washer with

wheel

2

Disconnect

rear

Disconnect

nut and

brake

tube

cylinder openings

to

prevent

race

oil seal in

new

a

outer

by

brass hammer evenly

bearing

Lubricate

cage

Place

cavity between seal wheel bearing grease after

bearing

apply

cone

cage with brake disc

brass drift to

a

race

side

surface and tapping the top of drift with a hammer

Remove brake drum

Not

Install

bearing

a

and bearing spacer on axle shaft and fit bearing cone To install bearing

entrance of dirt 4

tapping with while fitting

3

rear

wheel cylinder Cover brake tube and wheel

Fit wheel

lips with fitting seal

clamps at

I

2 Do not use used lock washer

again

hand brake cable

by removing adjusting

a screw

driver

Note

rear

3

Position axle shaft in vise with

9

rear

under axle

Suspension

Rear Axle Stand ST07630000

WHEEL BEARING I

Rear

If brake drum cannot be

removed

return

install two

holes

brake

easily adjuster

M8

I2S

bolts

the

on

drum and

x

in

RAl38

Fig RA 6

face of brake

flange tighten bolts evenly

until

brake drum is driven out

10

Unbending lock washer

Remove

Axle

lock

Bearing

nut

using

Nut

Lock

Rear

Wrench

ST38020000 5

Remove

bearing

nuts

retaining

wheel

I

cage to brake disc

AA141

Fig RA 9 Installing whetl bearing

4

Place

bearing shaft

and

Rear AJde AA139

I

Jq

AA135

Fig RA 4 Removing

nuts

II

Fig RA 7 R mouing lock

nut

wheel

to

Withdraw

gether disc

with

bearing

bearing

cage

and brake

Axle Shaft

using Rear

Bearing

lock washer

tighten Bearing

ST38020000

@

lock nut

Q and on

@

axle

using

Lock Nut Wrench

and bend up lock wash

er

Notes a

Be careful to

the faced side of

place

nut to washer side not

Puller HT72480000

bearing

nut lock washer

so

that washer is

damaged

b Coincide washer

lip with nut groove tightening nul and bend washer carefuljy so that lip will nol be damaged correc

HT72480000

ly by

r t

Tightening torque

Rvr

IS to 20 kg

G

o

l

AA343

Fig RA 8 Removing bearing 12

Remove oil seal in

bearing

cage

if necessary 13

To

race

after

AA418

Fig RA 5 Removing

rear

axle shaft assem

bly

brass

Remove oil

seal

necessary and install

against damaging

in axle case if new

the seal

seal

lip

Insure

to it

a

Installing reverse

wheel

bearing

removed oil seal

drift

withdraw drift with

7

remove

race

i

t i

S

side surface

a

and

11 iI

i

j

hammer be

fifii Litf 4

outer

apply

by tapping the lop of can

m

J08 to 14S ft Ib

proceeded

order of removal

follows

i

in the

procedure

I

as

AA142

Fig 4 RA

t J Mf

pu y

RA IO Layout ofock nut

Rear

Rear Axle

Apply wheel bearing grease in wheel bearing and recess of axle case S

Suspension

Install shaft in opposite side

8

adjust

end

axial end

Axial

end

play by applying

shim

0 02 to O IS

play

Installing

and

reverse

Differential carrier

fixing

Tightening torque of bearing cage fixing nut 5 4 to 6 4 kg m to

the

proceeded in procedure

Tightening torque

mOl

0 0008 to 0 0059 in

39

be

can

order of removal

to

I 7 to 2 5

nut

12 6 to 10

kg

kg

m

to 18 ft Ib

plug

Oil drain and fIller

46 ft Ib

axle case

m

43 to 72 ft lb

Lubricating portion AA143

REAR SPRING Fig RA

l1

Lubricating portion in and around wheel bearing

Raise rear of vehicle and

1

under

both

frame

support with

members

stands 2 6

Apply

gear oil to the

spline at the Apply a coal

inner end of axle shaft

of wheel bearing grease

on

end

Spring clips

the seal

Fig RA

shock

Disconnect

lower

CD 2

and

absorber

remove

at

U bolts

Measuring axial end play

13

surface of the shaft 7

Install

left

shaft

right

or

and

adjust axial end play by applying rear axle case end shim indicated by arrow

9

Install

other

parts in

reverse se

quence to removal

mark Axial end

play

3 to 0 9 0 0 012 to

mOl

035 0

in

REAR AXLE CASE

Standard shim thickness 5 mm 0 059 in 1

bearing

cage

fIXing

54 to 6 4

cedures

nut

kg

Rear axle case may be removed and using the following pro

installed

Tightening torque of m

Raise

I

39 to 46 ft lb

securely

rear

under

of vehicle and support both frame members

with stands Remove rear axle

2

removal of

rear

assembly See assembly

axle

Remove rear axle shaft at

3

See removal of

sides

and wheel 4

rear

both

axle shaft

Position

differentiai

carrier

jack

under

rear axle case

Raise jack and float axle

case

from

spring 4

Disconnect

removing

bearing

Remove

3

rear

spring shackle by

nuts

as

sembly

w

Installing AA144

Fig RA 12 Installing

rear

reverse

axle shaft

be

can

proceeded in the procedure

order of removal

Another

procedure

is available

as

listed below Rear axle case end shim I

Thickness

mOl

in

Raise

under

rear

both

of vehicle and support frame

members

with

stands O OS

0 0020

0 07

0 0028

0 10

00039

0 20

0 0079

O SO

0 0197

2

Remove

ear

axle shaft

at

both

AA147

Fig RA 15 Removing spring shackle

sides 3

Remove

differential gear carrier

assembly 4

Disconnect spring from body by removing spring front pin 5

Remove rear axle case

RA 5

Suspension

Rear

Rear Axle

Check axle shaft for

I

SHOCK ABSORBER

cracks Raise

rear

under axle case

mended that

pit

of vehicle and support on stands It is recom

hydraulic hoist

a

2

open

Disconnect lower end of shock

absorber

spring 3

by

removing

Q

nuts

wear

straightness

and distortion

Check the lip of oil seal for damage deformation and wear 3 Check bearing for wear and 2

damage

at

seat

REAR AXLE CASE

Disconnect

upper

absorber by removing

RA148

or

be utilized if available

damage

end of shock

nut

2 at

Check axle

frame

tion

Fig RA 16 Remvoing spring pin

cracks

case

or

for yield deforma

oil leakage and replace

if necessary 6

Remove rubber bush in

spring if

REAR SPRING

necessary and install new bush Coat rubber hush with a soapy solution

prior

to

Clean all rust and dirt from spring leaves using

assembly

1

spring in the reverse of removal noting the following

InstaH order

rear

2

RA146

Vehicle weight must be on rear wheels when tightening front pin

Fig RA

J

7 Removing shock absorber

shackle and shock absorber lower end

clamp rubber bush neutral or unloaded position nut in order to

nut

reverse

order of removal

Vehicle

weight

must be

tigtrtening

on

Tear

or

unloaded

position

kg

m

U bolts

replace with new

bracket

and

and

ones

3

Inspect all rubber parts for wear damage separation and deformation Replace them if necessary

SHOCK ABSORBER

Data

INSPECTION

Test shock absorber and compare

Shock absorber lower end m

12 to 16 ft lb

2

REAR AXLE SHAFT AND nut

WHEEL Inspect

faults and replace

following as

required

RA 6

Check for oil leakage and cracks

Also check shaft for straightness

BEARING the

specifications given in Service Replace if

and Specifications

necessary

m

S3 to 72 ft lb

kg

front

pin spring seat for wear cracks straightness and damaged If faulty parts are found threads

with the

83 t094 ft b

1 6 to 2 2

Check

shackle

I

nut

3 to 9 9 7

spring leaves for frae

cracks

shock ab

upper and lower ends in order to clamp rubber bushings in a

m

neutral

11 5 to 13 0 kg U bolt

the

of shock absorber in

or

wire brush if necessary

sorber

kg

83 to 94 ft Ib shackle

Installation

wheels when

11 5 to 13 0

Spring

a

Note

Tightening torque Spring fTont pin

in

Examine

tures

poinc

a

3

parts

for

age

Inspect rubber bushings for dam cracl s and deformation Replace

parts if necessary

Rear Axle

Rear

Suspension


Applied

model All models

Item

Rear shock absorber

Stroke

x

Maximum

length

190

x

7 48

47S

x

18 70

in

mOl

Damping force 3 m 0

at

10 ft

sec

Expansion

kg lb

75 to 101

Compression

kg lb

3S to S3

165 to 223

77 to 1l7

Option

Standard

Rear leaf spring 1 200

Dimensions x

Length

x

mOl

47 24

36 2

x

5 1

6 1

13 1

13 2

IS3

mOl

in

Laden camber

mmlkg

Spring

kg mOl lb

in lb

in

47 24

0 243

x

in

Free camber

x

36 2

play

mOl

0 24 1 0 512 140

24 440

6 440 0 24 970

2 6 to 10 0

2 1 to S O 118 to 280

5 S

0 94 970

146 to S60

thickness

mm

Recommended for

in

use on

0 0008 to 0 0059

0 02 to O IS

Rear axle case end shim

heavy load under high

center of

O OS

0 0020

0 07

0 0028

0 10

0 0039

0 20

0 0079

50 0

0 0197

gravity such

as

camper

loading

Tightening torque Shock absorber upper end nut

kg

m

ft lb

3 1 to 4 1

22 to 30

Shock absorber lower end nut

kg

m

ft Ib

1 6 to 2 2

12 to 16

Rear

kg

m

ft lb

3 to 9 9 7

53 to 72

spring

U bolt

Clip

RA 7

0 28 2

0 51 1

60

in

x

0 20 1

Rear axle End

72

1 200x60x

6 3

60 x

Width

Thickness Number of leaves

constant

x

Rear Axle

Spring front pin Spring

shackle

Rear

Suspension

kg

m

ft lb

kg

m

ft Ib

115 to 13 0 83 to 94

5 to 13 0 11

83 to 94

fIXing

bolt

kg en

ft lb

S 4 to

Wheel bearing lock

nut

kg

m

ft Ib

IS to 20

kg

m

ft Ib

0 7 to 0 9 S I to 6 S

kg

m

ft Ib

17 to 2 7

12

to 20

kg

en

ft Ib

2 0 to 2 7

14

to 20

kg

m

ft Ib

6 to 10 43 to 72

kg

m

ft Ib

1 6 to 2 2

kg

m

ft lb

8 to 9 S8 to 6S

Bearing

cage

Air breather

Differential gear carrier to axle

Propeller

shaft

flange

case nut

bolt

Drain and filler plug

Bumper Wheel

rubber

fixing

bolt

nut

4 6

39 to 46 108 to l4S

12 to 16

TROUBLE DIAGNOSES AND CORRECTIONS When

rear

axle and suspension is

suspected of being noisy to make

whether tires

a

thorough

the noise

shaft

it is advisable

road surface exhaust

in

the

propeller

Condition

Noise

transmission

bearings

Probable

one

Lack of

or

more

lubricating

and

rear

there is any

Tighten the bolts

to the

oil

Lubricate

grease

Replace rear

restriction in

Corrective action

securing bolts

of

first check if

or

breather

nuts

adjustment

leak

damage

Tighten the wheel

or

suspension

of oil

case

cause

Faulty shock absorber Incorrect

In

or

Loose wheel nuts Loose

rear axle

universal

suspension Noise which originates in other places can not be corrected by adjust ment or replacement of parts in the

test to determine

originates

engine

joint wheel

axle shaft end

as

the shock absorber

the

Adjust

specified torque

required

rear

axle shaft end

play

play Damaged Worn

or worn

wheel

spline portion

bearing

Replace wheel bearing

of rear axle shaft

Replace

if necessary

Broken leaf spring

Replace

leaf spring

Loose

Tighten

to

journal

connections or so no

Wheel and tire unbalance

Damaged

Instability

Oil

leakage

in

driving

Balance wheel and tire

rubber parts such

bush shock absorber

the given torque

moun

as

leaf spring

Replace

the

required parts

ting bush

Faulty universal joints

Adjust

Loose wheel nuts

Tighten

Worn shock absorber

Replace faulty

Worn or broken leaf spring

Replace

leaf spring

Clean

replace

Damaged Damaged

or

restricted air breather

oil seal in

or

differ

Replace

between the differential

Tighten

rear

axle

or

case

or

replace

to the

given torque shock absorber

air breather

the damaged oil seal

ential carrier Oil

leakage

from

carrier and axle case

gasket

8 RA

to the

specified

torque

or

replace

Rear

Rear Axle

Suspension

SPECIAL SERVICE TOOLS For

Tool number

Description

No

use

Unit tool

mOl

KV40101000 Rear axle

page

in on

name

This tool is used to Use with

sliding

remove rear axle

shaft

All

hammer ST36230000

Reference

Figure Fig

or

No

RA S

models

stand

SE402

2

ST36230000

Sliding

hammer


remove rear

axle shaft

All

Fig

RA S

Fig

RA 7

models

Use with rear axle stand KV40101000

SEll1

3

ST38020000

This tool is used to loosen and tighten

rear

axle bearing lock

nut

620

Bearing lock nu t

wrench

SE238

4

HT72480000

This tool is used to drive out

rear

All

axle shaft bearing

rigid

axle

Rear axle shaft

bearing puller

car

models parts

Iools

are

used for other

rear

axle

Iype

SE382

RA 9

Fig

RA 8

SECTION BR

BRAKE SYSTEM DATSUN PICK UP MODEL 620 SERIES

GENERAL DESCRIPTIDN

BR

ADJUSTMENT

BR 2

SERVICE BRAKE

BR

HAND BRAKE

BR 18

SERVICE DATA AND

SPECIFICATlDNS

4ISSAN l

I


LTD JAPAN

2

4

BR 2D

TROUBLE DIAGNDSES AND CORRECTIONS

BR 22


BR 25

System

Brake

GENERAL DESCRIPTION The

ped

with

wheels on

the

620 series vehicles

the

are

equip

brakes on the four

hydraulic

and mechanical hand brakes rear

and the

type with

duo servo

controlled by a hand brake lever locat ed in the driver s compartment

wheels The front brake is

servo uni

the

rear

built in

the

hand

The mechanical hand brake is

brake

For

added

safety

tandem

Master Vac

cylinder

1lI3ter I

the

are

standard equipment

on

all models

The Master Vac is installed to increase

braking force The N LS V greater safety and reliability

ensures

and

N LS V

Nissan Load Sensing Valve

ADJUSTMENT CONTENTS BR 3

BRAKE PEDAL

BR 2

HAND BRAKE

FRONT BRAKE

BR 2

BLEEDING HYDRAULIC SYSTEM

REAR BRAKE

BR 3

Parking

brake

3 After completing adjustment operate brake pedal several times to

BRAKE PEDAL

stroke of 137

Qi

without

ing or

l

A

148

Full stroke at pedal pad

B

134 10 140 5 28 to 5 51

Depressed height

C

43 to 49

Free

II t

height

its entire

smoothly

showing squeak noise

twist

interference

Raise

1

2

Push rod adjusting nut Switch adjusting nuts

3

BraKe lamp

switch

vehicle

BA765

wheel clear

rubber boot from brake

Remove

disc 3

tap adjuster housing and forward Turn down adjuster

Ughtly it

move

brake in

until

floor

wheel with

mm

over

5 39 in

FRONT BRAKE

2

Unit

mm

5 83

1 69 to 193

1

travels

that it

ensure

f

BR 3

a

shoes

wheel when

screwdriver

and

spread

turning adjuster considerable drag is Jelt Stop

a

and lock up brake drum Fig BR

Adjusting brake pedal

l

For both

Note I

Under

the

condition

that

the

push rod of brake lamp swi tch is pushed in position the height of brake pedal from toeboard to 148 mm 5 83 in operating the switch adjusting nuts Then tighten nuts securely

with its adjusting nut 0 6 to 12

play

Then

so as

to become

0 024 to 0 047 in in

mOl

5 kg 1

Tightening

4

torque

1 6 to 2 2

kg

to

m

drum

drum turns

m

the length of push

Return

adjuster

wheel 12 ratches

obtain correct clearance between

brake

12 to 16 ft lb

Note

Take care not to allow the

rod to get into master

Adjust

wheel is turned downward

and brake

brake drum and make

9 to I I ft Ib

2

right and left brakes spread when adjuster

tigh1en nut securely

Tightening torque 1 2 to

brake shoes

rod

free condition

BR 2

push cylinder in

without

shoes

sure

Turn

that brake

dragging

when

brake shoes interfere with brake drum clearance

then

readjust

5

Install rubber boot

Brake

System Clean all dirt around master cyl inder reservoir remove cap and top up I

t

1

I

reservoir fluid

0

0

free

Install

from a

Place BA655

Fig BR 4 Adjusting lock

BR 2 Adjusting front brake

Fip

is

c

nJ

and dust

from bleeder valve so that outlet hole

I

o

Thoroughly clean mud

2

t 6

brake

recommended

with

nut

any

foreign material

bleeder hose the

on

bleeder valve

other end of hose in a

container filled with brake fluid

Depress brake pedal two or three then keep pedal fully depressed

3

times 4

With brake

pedal fully depressed expel air

open bleeder valve to

REAR BRAKE With

adjust

hand

rear

the service

brake

For

brake shoe clearance

procedures

Fully release

3

fully released

hand No

rotate rear wheels

brake

and

drag should be

Notes a

present

refer to Front

b Do not

Notes

Brake

a

Before

adjusting

hand brake

reuse

brake fluid drained

during bleeding operation

com

plete the adjustment of rear brakes b After adjusting hand brake operate

c

Bleed air as follows

cylinder front cylinder rear

1

Master

2

Master

stable

3

N LS V

Hand

4

Front wheels

S

Rear wheels left

6

N LS V

rear

7

N LS V

center

the

c

Pay attention to brake fluid level in master cylinder reservoir during bleeding operation

brake

released

make

to

operated pulled and

while being Make

noise

sure

cable

be

must

brake

smoothly mal

lever

that

dragging

other faulty condition

no

abnor

twisting

or

d Exercise

occurs

fluid

on

front

care

one

not to

first

splash brake

exterior finish

as

it

will

damage the paint Fig BR 3 Adjusting

rear

brake

5

Close

brake

ly

BLEEDING HYDRAUL Ie SYSTEM

Parking brake I

Raise vehicle until

rear

wheels

are

clear of the floor 2

Apply hand brake lever operate

lock nuts to be 80 to 100 3 94 in

mrn

lS 3

to

in hand brake lever stroke

and tighten lock nuts securely

Applying

force to hand brake

lever 20 to 30 kg 44 to 661b

Hydraulic brake system

must

be

with bleeder

7 no

valve quickly

pedal

screw

to return slow

closed

Repeat bleeding operations until air bubbles show in hose

Notes Brake fluid containing air is white

bled whenever any line has been dis connected or air has entered into

a

system

b Brake fluid containing

no

of bleeder valve

in

When

feel

it

pedal is

an

action has

a

and has visible air bubbles

out

spongy

BR 3

air nms a

solid

stream free of air bubbles

indication that air has

entered the system Bleeding the hydraulic system is an essential part of regular brake service

as

is on down stroke

Allow brake

6

HAND BRAKE

pedal

bleeder

8

Repeat above

steps

maining brake lines to

on

expel

the

all air

re

Brake

System

SERVICE BRAKE CONTENTS BR

4

REMOVAL

BR lO

REMOVAL

BR

4

DISASSEMBl Y AND ASSEMBLY

BR 1O

INSPECTION

BR

4

INSPECTION

BR lO

INSTAllATION

BR

4

INSTAllATION

BR ll

BR

5

REAR BRAKE

BR 12

REMOVAL

BR

5

REMOVAL

BR 12

DISASSEMBl Y AND ASSEMBLY

BR

6


BR 13

INSPECTION

BR

6

INSPECTION

BR 13

INSTAllATION

BR

5

INSTAllATION

BR

7

BRAKE

PEDAL

MASTER

BRAKE

CYLINDER

LINE

BR 13 BR 14

MASTER VAC

REMOVAL

BR

B

DESCRIPTION

BR 14

INSPECTION

BR

B

INSPECTION OF OPERATION

BR 14

INSTAllATION

BR

B

REMOVAL

BR 16

BR

9

DISASSEMBLY

BR 16

DESCRIPTION

BR

9

INSPECTION

BR 17

N LS V

BR

9

ASSEMBl Y AND ADJUSTMENT

BR 17

INSTAllATION

BR IB

N LS V

FRONT

TEST

BRAKE

BR lO

BRAKE PEDAL REMOVAL Remove

pedal

return

spring

i

b

t 5

I

pin spring

2

I

Fulcrum

3

2

Return

3 4

Pedal bushings Clevis pin

5

Brake

4

BR766

Fig BR

Broke

5

BR657

pedal mounting

pedal

Fig BR 6 Broke pedal

2

Remove

cotter

pin and separate Vac push rod 3

Remove

pin from clevis

pedal

from

INSPECTION Check brake

fulcrum pin and

Loosen fulcnun

pin

pedal

for the

following

items

pedal

I

servicing as necessary Check pedal bushing for

deformation Note

INSTALLATION

Master

clockwise

2 or

Check

or

wear

damage

pedal

Install brake pedal in the reverse attention sequence of removal paying to the following instructions 1

shaft sleeve for

wear

roughness

Insert fulcrum pin into hole in pedal and bracket from right

brake side

3

Check for bent brake

4

Check for

fatigued

4 BA

pedal

return

2

spring

side

Install clevis pin from left hand

Brake Hook return spring to brake pedal assembly from accelerator pedal side

To install it

3

Apply

4

coating

a

of recommended

multipurpose grease to the inner and clevis outer faces of pedal bushing and hooks of pin Charge the clearances

spring bushings with

I

System

proceed

Turn retention

retention cap

fully

as

ring

used in the

3

1 j

1tr

L

I I

00

Nabco

1

Reservoir cap

2

Reservoir tank

3

Secondary piston return

4

5pring Stopper

CD

Greasing place

7

6 5

lnstali brake lamp switch

6

Adjust

the brake to

screw

Secondary piston Primary piston return

spring after in

pedal

7

BR926

Primary piston

the instructions

Fig BR B Sectional view of tandem

under Adjustment

Tightening torque Fulcrum pin 1 9 to 2 4 kg

in the

Tokico

5

Refer

ring fully

Turn retention

I

BR298

stallation

in retention

return in

U BH

projection

TIGHTEN direction

@

Fig

the

and push retention cap in the tank

in the REMOVE

Grease

n

Align

cap with the slit in the reservoir tank

direction

grease

m g

2

follows

master

cylinder

m

14to 17ft ib

REMOVAL 1

Disconnect

front

and

rear

brake

tubes from master cylinder Notes

MASTER CYLINDER

a

The diameter of cylinder is 19 05

GG94310000

y in for all models The tandem master cylinder contains two fluid mm

Never

Braking force the

front brake

brake

is

failure

system

system Failure

main

BR658

in either

the

or

the

in

When sure

constantly occurs

b

o

lines independently

tained when

rear

2

still operative or failure in the rear brake system will leave the front brake

nut

a

retention cap remove

this cap

proceed

as

follows

I

Tum retention ring

fully

in the

REMOVE direction 2

disconnecting

to

use

a

adjustable

brake tubes be

container to receive

Remove master

Then master

taken out

system still operative

To

or

parts and area clean

front

with

open end

draining brake flnid Use of rags is also suggested to keep adjacent

Fig BR 9 Master cylinder

brake system will leave the rear brake

The reservoir is equi pped

use

wrench

reservoirs which connect the front and rear brake

When removing brake tubes use Nut Flare Torque Wrench

Pull out retention cap

BR 5

cylinder securing cylinder can be

Brake

System

DISASSEMBLY AND

ascertain the brand of the brake

ASSEMBLY

master

use parts of the former ones

1

same

Thoroughly

clean

all

00

oC

1

damaged parts Replace

11I

is

r

b

r

way of deteriolllting parts Use brake fluid or alcohoL When alco hol is used for

leaning

BA927

Secondary piston stopper

11

Primary piston

7

Bleeder

12

3

Oil

8

Secondary

Piston stopper Piston stopper ring

4

Packing

9

Secondary piston Primary return spring

10

screw

return

13

spring

if found

Check

piston

If it

ance

Master

BR 10 Master cylinder

3

off

stopper

ring

using

Valve cap Tokico

a

screwdriver

3

screw

and take

replace

cylinder

valves shows

5 to 3 S kg 2

in the order shown

or

m

S

18 to 2S ft Ib

Discard

moved use a

from

new

0 7 to 0 9

piston cup if it is re piston sembly and

damage

cylinder

clear

than O IS

mm

either piston

or

inner diameter

Yoin

mm

fatigued

or

be

master sure

Replace

cylioder

to

discard

is disassem

and

cups

any other part which

evidence of deformation

damage Replace damaged

oil

wear

reservoirs

and caps

Bleeder Note

When

bled

Nabco

stopper primary piston assembly spring and secondary piston assembly

to

more

Check for weakened

4 m

S8 to 6S ft Ib

out

wear or

faulty

sary

8 t09 kg

Remove stopper

compressed

damaged springs and replace if neces

Tightening torque

and drain out brake fluid

is

0 OOS9 in

19 0S

and filter

are

air

cylinder Fig

reservoir cap

longer

After parts

Check cylinder and position for

evidence of abnonnaI

2

Reservoir cap Oil mter

6

2

with

dry

Replace

Valve cap

these parts

do not immerse them in it

I

reservoir

parts with

since this will be the

sure

cIeaned

Pry

part that

any

Do not clean robber

minerai oil

than 30 seconds

2

a or

faulty

L

Remove

in

WOol

O

01

1

the

as

parts

suitable solvent and check for

Note

5

make

INSPECTION

00

1

Be sure to

cylinder body

kg

m

S to 7 ft lb

INSTALLATION

one

Notes 4

Unscrew plugs to gain check valve for disassembling Note

access

reason

a

sequence of disassembly

ing particular ing notes

packings

with

or

rubber grease

contact surfaces of

facilitate

parts

of master

assembly

cylinder

pay

attention to the follow

Install

master

cylinder

in the

re

sequence of removal Bleed air out of master cylinder by

verse

sliding

to

dis

one

Assemble master cylinder in the

reverse

and

Apply brake fluid to

U

c

S

Replace gaskets new ones

b

Never detach reservoir tank

it is removed for any canI it and install a new

to

loosening

bleeder

screw

after

it

is

installed in its original position

Tightening

torque

The blllke master cylinder is avail

Brake master cylinder attaching

able

nut

in

both

NABCO make and

TOKlCO make

changeability

of

There is

repair

no

kits

inter

or com

ponent parts between NABCO and TOKlCO

JIIlkes

the

kit

repair

or

When

replacing

component parts

BR 6

0 8 to 1 kg

m

6 to 8 ft Ib Brake tube connector I S to 18 kg

m

II to 13 ft Ib

Brake

System

BRAKE LINE

Detail

A

Detail

D

Detail

G

Detail

B

Detail

E

Detail

R

Detail

C

Detail

of

Detail 1

Detail

K

Detail

L

BA767

Fig BR ll Brake line BR 7

Brake stead

REMOVAL

new

Removing flare nuts on both ends and clips effects the removal of brake

replace one

after

1

damage an

tube and brake hose 2

Rear brake hose

can

the

by disconnecting turning round the hose Note

be removed

tube

Nut

use

OpeD end

an

INSTALLATION

Front brake hose

Torque

Fig BR 13 Rear brake ho In

Wrench GG943IOOOO Never

seating surface Never reuse

old copper washer

Brake hose

Flare

use

copper washer with a checking for sign of

and then

When removing brake tubes and

hoses

on

System

adjust

or an

able wrench

brake hose first jack up vehicle to take off the weight of vehicle from wheels so that suspension is in rebound

all

hoses

for

swell

cracking ozone rubbing marks or re those with found placing any ofabove badly beyond use Also inspect end fittings and be sure that no fluid leak through staked end has taken place replace if necessary Hose with badly rusted fitting should also be replaced

with 2

Clean

and dirt with

tubes

to remove dust

cylinder

with the

kg

The

m

Hose to

bracket twist or

brake

secure

with lock

Note

hose

plate

so

to

as

the

clamped

connecting

as

rotating or mOving parts tire and rim

as

57 in and 1

40 mm

more

more

brake hose at

pay keen attention not to twist the hose when additional is

be

must

Hose to stationary part 2S mm 0 98 in and

both eiuIs

tightening

such

not to

abnormally bend the hose

After

clearance

wow

follows

12 to 14 ft Ib

Then

through its rotating steering wheel extreme lock positions

up and down

between two

Tightening torque 7 to 2 0 1

moving wheel

full stroke and

specified torque

ing for collapse wear cracking swell or rusting Replace if foun d with any of wove Use care not to damage brake tubes while operation are

enough

The check should be carried out while

isopropyl alcohol check

Check if tubes

that there is

To connect brake line first connect

a new one

all

sure

also be kept in straight ahead position brake hose to wheel Examine

wheel should

Steering

After brake hose has been installed check to be

clearance between hose and adjacent parts to avoid contact with other ones

INSPECTION

1

e

installing

In

the above

clearance

be obtained it may be caused

cannot

by the

required

that

case

hose

twisted

Accordingly

the correction with hose

out

carry

following

connection again

the above

instructions

secure

ly Mter

brake lines

all

have

Brake tube

been

installed

retighten aU connections if necessary to assist in obtaining correct torque In retightening at front wheel cylinder first remove hose clamp and loosen flare nut on opposite side to avoid twisting hose Hold pedal as far downward as possible 80 kg 176 lb or more examining evidence as to whether fluid is leaking through brake lines or con nections Leakage in any manner can not be permitted here In case fluid leaks tightening to specified torque tighten additionally up to 2 5 kg m Under no circumstances J 8 ft lb not should be tightened over 2 5 kg m 18 ft Ib torque since this elongates end reuse

fitting

making

it

impossible

to

no

circumstances should

rear

brake hose and 3 way connector be

retightened

over

specified torques

In

installing its

a

end

brake tube

use care

mating noting the fact that nut can be turned freely by a light finger twist

squarely

on

seat

Then

tighten

Brake

to correct torque with a

Pipe

Torque

Wrench

GG943 10000 Fig BR 12 Front brake hose torque Flare nut 5 to 1 8 kg m 1

Tightening Rear brake hose First

secure

11 to 13 ft Ib rear

brake

hose

to

3 way connector on rear axle case to the

specifications

hose

Mter

tighten it additionally since

do not

connector

connecting at

Tightening torque I 7 to 2 0 kg m 12 to 14 ft Ib

BR 8

3 way

this oper

ation causes hose to be twisted

brake tube

Under

In

to locate

In addition

care

should also be

damaging or col lapsing during operation Be sure to make enough clearance between all tubes and other adjacent exercised

to

avoid

brake tube

parts to avoid contact In installing tube through hood ledge grommet be sure to position it at the center of grommet

Brake be

connecting brake tube

After

check the clearance to prevent

sure to

clearance

The

from

damage following portions distance

or

Tube to

be

must

at

The

System

N LS V

frame being

is

installed

inclined at 10

the

on

degrees

Over 5

specified

Tube to edge ofeach Over 10

TI II

Master

and frame

cylinder

0 20 in

mm

r

in

I

y 1

panel

39 0

mm

v operation is summary of the N L S BR 14 in and BR 15 Figures given

the

more

body panel

A

Tube to tube

Loop pitch OVer 5

0 20 in

mm

J

Between front tube and rear

tube

Over 9

35 0

mOl

in

Tube to moving parts Over 10 mm 39 in 0

Loop

tube to hood ledge

Over 10

39 0

mm

I panel

Attaching angle

l

in

Notes

D

Brake tubes

a

are shaped at factory specified clearance and may not require reshaping Discard if they call for excessive reshaping In reshaping a brake tube take care to avoid damaging galvanization or collapsing section

to

b

Wheel

cylinder

secure

Mter brake lines have been

asssem BR928

bled

to

check

fittings and flare correct

make nuIs

sure

ale

that

lightened

all to

Fig BR

14

Construction of N L S V

torques Performance

Tightenint torque Brake tube to connector I Ston

kg

pressure is

as

curve

m

S c

Brake tube to brake hose

2 0 kg

to

0

m

C

12 to 14 ft lb

to

5 to 2

4S O

kg

U1U oadea

o

Connector and clip fixing bolt 3S O

A

0

II to 13 ft Ib

17

of brake fluid

follows

l

0

m

3 ft lb

fixing

3 way connector

Front wheel cylinder

bolt

fluid

on rear axle case

0 8 to 1 kg

BR769

pressure

Fig BR 15 Perfonnance

curve

offluid pressure

m

6 to 8 ft lb N L S V TEST

N L S V

When

Operating test

DESCRIPTION The

Nissan

N LS V

the following occurs

The test should be conducted under

Load

serves

to

Sensing Valve change braking

in response power of the rear wheels to changes in the load and fluid

pressure improving braking stability and shortening stopping distances

a

then with concrete or

vehicle with pay load and a dry only driver asphalt road applying on

brake suddenly N LS V

is

wheels lock

ft

whether

loaded

or

Stopping distance should

these conditions Drive

rear

place applied to

is first

the

actually

functioning normally if

stops

simultaneously wheels

the

be measured

pedal

place the vehicle

Front with

43 0

unloaded

where the brake

from the

flat

at 40 km h 25 MPH

BR 9

stopping

distance is shorter than 13 1 m

or

wheels ahead of

lock rear

Brake

Ibove

mentioned

st is available

N L S V is

when the

except system correctly adjusted

Wheel cylinder

brake

entire

op

System simply by

be disassembled

can


the

described below Remove

retainer

and

and dust

cover

piston from wheel cyl

take out

damage sliding piston cup piston Thoroughly wash u disassembled

inder Be careful not to

part of

FRONT BRAKE

and

parts in brake fluid

or

alcohol

parts with

Do not wash rubber

Note

mineral oil since they

deterio

are

rated

8 9 10

After shoe return spring

When alcohol is used however do

Adjuster assembly Adjuster head Adjuster head shim Lock spring Adjuster housing

not immerse rubber

1

Brake

disc

11

2

Brake

shoe assembly

12

3

Wheel cylinder assembly Brake shoe upper return

14

spring

15

Brake shoe lower return

16

Adjuster wheel Adjuster screw Retaining spring Lock plate Adjuster shim

spring

17

Rubber boot

4

5

13

parts in alcohol After parts

longer than 30 seconds are

cleaned

dry them with

com

air

pressed

Assemble wheel

in reverse

cylinder

sequence of diassembly When securing connector bolt sert

in

location tip to the hole of

its

wheel cylinder firmly and tighten Fig BR

I6

Front brake

REMOVAL I Jack up front of vehicle just high enough to remove tire and support it with safety stands 2

securely Carry out operations carefully so that component parts are not damaged or no dust and other foreign materials enter cylinder

Note

Remove wheel and brake drum If

M8

in holes on the

1 25

x

install two bolts

adjuster

face

flange

3

In order

spindle 4

from

Unhook upper

lower

Disconnect

and after

Loosen

wheel 7 shim and

rubber

remove

inter

or com

changeability

ponent parts between NABCO and

3

Rubber boot

TOKICO makes

BA312

When

Fig BR 17 Removing wheel cylinder

replacing ent

the

parts

repair

body same

Be sure to use

make

as

kit

ascertain

brand of the brake wheel


or

the

cylinder

parts of the

the former

ones

remove

hose

from

@

nut and remove

boot

adjuster

rr l

t

@

lock plate and retaining spring then

repair

no

kits

Wheel cylinder attaching bolt

cylinder

Remove

There is

Wheel cylinder

brake

securing

of

Brake hose

wheel cy linder 6

is

2

knucRle

and then

cylinder

1

re

Refer to Front Axle

shoe return springs brake shoe assemblies S

operation

ease

assembly

hub

move

to

driven out

wheel

brake

TOKICO make

of brake drum and tighten bolts even

ly until brake drum is

The

available in both NABCO make and

brake drum cannot be easily removed return brake

it

adjuster assembly

from brake disc Wheel cy

linder

housing 2

Piston

3

Piston cup

4

Dust

5

Retainer

cover

a

INSPECTION BR649

6

Connector

7

Packings

8

Connector bolt

I

9

Bleeder

meter is

10

screw

Bleeder cap

Fig BR 18 Front wheel cylinder SR tO

Brake drum

Replace brake drum beyond the limit

whose dia of 1 5

mm

0 OS9 in with respect to the standard 10 00 inner diameter of 2S4 0 rom in

Brake out of

The allowable maximum

2

of brake

round

drum

is

System Standard dimensions of shoe springs

0 02 mm

Installed

0 0008 in Re condition

or

replace

in

mOl

if specified limit is exceeded 3

Measure for

tapered

If specified limit of 0 02 in

is

exceeded

re

condition

4

Contact

linings

in

lengthlload

coils

0 079

37

3 2

091 0

35

14

O OSS

S 37

a

134 S

Lower

inlet

2 0

kg

mm

in lb

IS9 S 14 to 16 6 28 31 to 3S 5 21 to 23 IS9 28 6

30 5

Sl

46 to

which

with

83 2

After shoe

3 28

99 4 to S

27 S

3 90 9 to II

extent that it is

an

120 to 150 sand

No

a

No of

brake drum

surface

finished to such

mOl

5 136

Upper

into contact should be

come

ground by

at

from

away

replace

or

0 0008

mm

distance of 4S mm

position where the 177 in is kept

of spring

brake drum

measured

as

Dia

Free length

Item

brake drum

paper

Using a drum racer finish brake by machining if it shows any

S

drum

sign of score marks partial wear stepped wear on its contact surface

Wheel cylinder

Adjuster sliding

or

S to 12 I

Replace

cylinder

any

which is scratched scored After brake drum is completely

Note

conditioned

or

re

check

renewed

drum and shoes for proper contact

pattern

its

sliding

2

or worn on

Replace

parts if piston to

worn

beyond O IS

is

mm

0 OOS9 in

2

When installing wheel cylinder be

sure

to secure the

cylinder with right hand disc and the

mark to

cylinder

19 0S

mOl

inner diameter

Y in

with

mark

L

with other

When

I

cracked

brake

shoe

incompletely

linings

seated

are

uneven

andlor deteriorated due to heating or soiled with oil and brake fluid replace grease 2 Replace linings if the thickness is Iy

worn

excessive

worn

down to less than 1 0

mm

Replace piston cup which is worn or otherwise damaged 4 Replace if contacting face of cyl inder and shoe is worn locally or in step S Replace damaged dust cover fatigued piston spring or faulty

connecting no

its threaded

adjacent parts

or

contact is existed

Tightening torque Wheel cylinder SA to 6 6 kg

on

brake

m

39 to 48 ft lb

Connector bolt

portion

19 to

0 039

14

5 kg 2

m

to 18 ft Ib

Brake hose 1 7 to 2 0

Note

When brake shoe lining is in stalled grind brake shoe lining face to diameter

equal

Width 4S

4S

x

177 3

Thickness

x

x

x

244

0 177

x

Length

x

mm

9 61 in

Check adjuster for smooth oper

ation

I

Replace broken

or

fatigued

brake in the

When assembling adjuster

bly

reverse

0 7 to 0 9

4 2 to S O

brake grease to adjuster bore adjuster wheel and ad

disc

kg

m

30 to 36 ft lb

brake shoe

Before installing

3

When installing

m

Brake disc

assem

housing juster screw

kg

5 to 7 ft Ib

apply

to brake

shoe return springs which

m

Air bleeder Install front

sequence of removal paying particular attention to the following instructions

lining dimension

kg

12 to 14 ft lb

INSTALLATION

to that of brake

drum

are

As to the

instructions of brake hose

line

in

4

disc

hose referring the related topic Brake

threaded parts 6 Replace tube connector which is worn on

twist

left hand

to

R one

brake hoses may interfere

Otherwise

3

Brake assembly

to 261b

piston

or

contact surface

cylinder clearance

Wheel

resistance

kg II

as

brake grease to wheel

adjuster assembly

semblies

apply

brake grease to

cylinder

and adjuster brake shoe in

apply

disc adjuster and retaining spring slid ing surfaces to slide adjuster smoothly resistance

stalling grooves brake

shoe

two

places

and brake disc and

assembly Exercise

adjuster sliding Adjust by adjuster shim when sliding

allow grease

resistance is in

linings and adjuster

Measure

rrect

BR ll

to come

contact care

faces

not

to

into contact with

Brake 4

brake shoe clearance and

Adjust brake

bleed

System

system

instructions under

Refer

to

the

topic Adjustment

in

this section

Upon completion of the above ad justments make sure that brake oper ates correctly and no brake fluid leaks

BA313

Fig BR 19 Greasing points

REAR BRAKE 1

2

Brake disc Brake shoe assembly

3

Wheel cylinder assembly

4 5

Return upper spring

6

After shoe return spring

7

Retainer

8

Antirattle spring

9

Spring seat Adjuster assembly Adjuster head Adjuster head shim Lock spring Adjuster housing

Return lower spring

10 11 12 13 14

17

Adjuster wheel Adjuster screW Toggle lever

18

Extension link

19

Return spring

20 22

Adjuster spring Lock plate Adjuster shim

23

Rubber boot

24

Antirattlc pin

15 16

21

BA315

Fig BR 20 Reor brake

REMOVAL

7

I

Jack up

enough

lever withdraw clevis pin Disconnect toggle lever

8

toggle rear

of vehicle just

to remove lire and

high

support

hand brake

from

rear cable

with

safety

2

Remove wheel loosen hand brake

Turn

disc

pin by 900

10 shim

and

remove

and

cylinder

by loosening

from

installation

extension link S

Remove return springs

6

Remove

shoe assemblies

secondary brake shoe

assembly must be separated from toggle lever When separating after secondary brake shoe assembly from

BR316

Fig BR 21

Remouing toggle leuer BR 12

rubber boot

adjuster plate and adjuster springs remove adjuster assembly from Remove lock

brake disc

Open brake shoe assemblies out ward against return spring and remove 4

brake

wheel

flare nut

nuts

antirattle springs

Note that after

Remove

brake

stands

and detach brake drum 3

cylinder by loosening 9

it

Disconnect brake tube at wheel

Brake 3


Check

System

adjuster for

4

smooth oper

ation

Replace shoe

are

broken

or

return

springs which

fatigued

Wheel cylinder Standard dimensions of shoe springs Remove dust

and

head

piston Refer

and

cover

piston

out

assembly

Wheel Cylinder

to

pull

Free

of Front

Item

in

mOl

Brake

mOl

Installed

No of

Dia of spring

length

in

lengthlload mmlkg in lb

coils

175

Upper

l

345

7 2 3

6 22

ID

83 2

After shoe

0

11 184

5 32

158

Lower

CD

2 0 0 079

6 89

176 18 to 20

30

0 091

14 0 055

6 93 40 to 44 99 4 to S

5 27

3 276 5 20

AntiratUe Dust

2

Piston head

cover

3

Piston

Piston

5 6

Wheel cylinder housing Bleeder cap

7

Bleeder

8

Connector

9

II

12 3 S to

5 4

8 to 9 9

47 0

p

2

Wheel cylinder

screw

When assembling toggle lever and

after brake shoe assembly I

Washer

10

3 5

3 90 9 to

BR318

4

Cll

1 6 0 063

0 807

1

to 13

24 24 to 29

Replace

cylinder

any

which is scratched scored

Connector bolt

piston

or or

worn on

its

Fig BR 22 Rear wheel cylinder

sliding contact surface 2 Replace worn parts if piston to cylinder clearance is beyond O IS rom

brake shoe assembly to 0 to to 0 012 in

with a

clear

lever and after

between toggle

ance

adjust 3 0

properly

mOl

0

selected

toggle pin washer

0 00S9 in

cylinder

Wheel

INSPECTION

19 0S

rom

inner diameter

Xin

Toggle pin

Brake drum 3

Check

brake

drum in the

same or

outlined in the Front Brake

manner as

Drum

When

cracked

ly

worn

excessive

4

Replace if contacting face of cyl worn locally or in

linings

are

incompletely seated uneven andlor deteriorated due to heating

soiled with oil

or

0 091

3

0 102

faulty

4

2 9

0 114

threaded parts 6 Replace tube connector which is

S

3 2

0 126

Replace damaged fatigued piston spring

worn on

its threaded

dust

cover

or

portion

replace

lining is in shoe lining face

semblies

apply following places

brake

equal

10 lha I of brake

drom

Width x Thickness

x

Length

4S x 4 5 x 244 rom

177

x

0 177

x

9 61 in

the

reverse

paying particular

attention to the

Rear

same

dimemion

in

brake

sequence of removal

I

Lining

rear

as

following instructions adjuster assembly is the

front Refer to the paragraph

covering Front Brake Installation

Adjuster sliding resistance S to 12

kg

II to 261b

BR 13

brake

grease

to

as

the

Brake shoe installing grooves of

1 Install

brake shoe

Before installing

3

When brake shoe

to diameter

in

0 079

3 2

INSTALLATION

grind

rom

2 6

down to less than 1 0 rom 0 039

stalled

2 0

I

if the thickness is

in

Note

Thickness

2

5

shoe

brake

Replace linings

WOol

No

damaged

step

grease and brake fluid

2

cup which is worn

inder and shoe is

Brake assembly I

Replace piston

washer

adjuster and wheel cylinder 2

Extension link

3

Lower surface of spring seat

4

installing

grooves

Contact surfaces between brake

disc

and

brake

shoe

assembly

six

places At this time

be

sure

not to coat

brake grease to brake linings

Brake

System

f Note

The Master Vac

diaphragm dif fonner ones for improved

fers from

braking

are

label color

follows

force Do not install fonner

Master Vac

on

1976 models

identified by the

Master Vacs as

1976 model

The

Caution Label

Former models

YeJlow

BR317

Fig BR 23

4

ing point Gre

Tightening torque Wheel

cylinder

S to 1 8 kg J

m

BR321

II to 13ft Ib

13

operating rod spring Poppet return spring

1

Plate and seal

6

Seal

14

Exhaust valve

2

Push rod

7

Vacuum valve

15

Valve

3

Diaphragm

8

16

Reaction

4

Rear shell

9

Poppet assembly Valve body guard

Diaphragm

5

Diaphragm plate

17 18

Connector bolt 1 9 to

5 2

kg

m

14 to 18 ft Ib Brake tube

5 to 1 8 1

kg

m

II to 13 ft Ib

Air bleeder 0 7 to 0 9 kg

10

Air

silencer filter

11

Valve

12

Valve return

plunger disc return

spring

Front shell

Fig BR 24 Sectionall1iew of Master Vac

m

S to 7 ft Ib

Brake disc 5 4 to

4 kg 6

INSPECTION OF OPERATION

m

39 to 46 ft Ib

Checking

yscuum

pressure

S

Adjust brake shoe clearance and bleed brake system Upon completion of the above

make

adjustments

sure

that brake operates correctly and brake fluid leaks

Connect

I

a vacuum

gauge

in the

Vac

as

shown in Figure BR 25

line between check valve and Master

no

MASTER VAC 1

Check valve

2

Vacuum gauge

DESCRIPTION A

vacuum

Master Vac is

suspended

the master

installed behind

cylinder

BA169

As the brake

pedal is depressed fluid is forced under high pressure through the brake pipes to the wheel cylinders to retard or

The loaded

stop

the vehicle

Master Vac

diaphragm

in diameter pressure

Fig BR 25 Air tight

contains a

of IS2 4

It operates

produced

n the

mm

spring 6 in

negative engine intake on

2

Start engine and increase engine

speed gauge

Stop

engine

indicates

SOO

inHg

capable even

mmHg

vacuum

19 69

I

if the Master Vac is

Fifteen seconds

stopped

after

engine

is

observe the rate of drop in air

registered by vacuum gauge pressure drop of 25 mmHg 0 98 inHg is exceeded refer to the follow

cylinder is high pressure

master

of producing

t up

Air tight test

If tandem

t

pressure

manifold The

when

t

a

ing chart

faulty

failure BR 14

to determine

the

cause

of

System

Brake

Probable

Corrective action

cause

leakago

at check valve

2

Air

leakage

a

3

Air leakage between valve body and

Repair

seal

partes at valve

Air

5

Damaged piping

leakage

or

plunger

I

Replace seal

t push rod seal

4

1

Replace check valve

I Air

Manifold side

seat

joints

replace

or

1

Repair

or

replace

Repair

or

replace

seat

seconds

after

engine

is

stopped and brake fully applied ob serve the rate of drop in air pressure registered by vacuum gauge

Probable

If 0 98

a

following

of 25

is exceeded

inHg

Connect an oil

mmHg

refer

to

line

2

leakage

the

Install

2

chart to determine the cause

Air

leakage

at

check valve

Replace

vacuum

Relationship and in

Replace faulty part

seat

a

each pedal operating force between oil pressure

to

respect

Reinstall and check push rod

off

With

pressure gauge

of 500 mmHg 19 69 inHg oil pressure with measure an

held

Replace

poppet assembly

brake

pressure

for proper turn 4

on

Start engine and increase engine speed until a vacuum pressure of 500 mmHg 19 69 inHg is registered on

Corrective action

cause

dropped

spring scale

a

3

at check valve

Reaction disc

master

on

pedal

of failure

Damaged diaphragm

3

pressure gauge in

connection

at

cylinder

vacuum

1 Air

BA289

valve

drop

pressure

Spring

Valve

Operating test

brake

Fifteen

2

Fig BR 27 Sectional view of check

1 2

Master Yac side

faulty

as

s

pedal operating force is illustrated Figure BR 28 If test results are not specified in Figure BR 28 check

Master Vac for condition in

and valve body

a manner

described under Inspection

as

before

removal of this unit

Also check brake line for evidence Note is

When

replacement of any part required be sure to renew

Master Vac as an

assembly

15 seconds new

one

3

When

Master Vac

Inspecting check valve

valve

Remove

clip and

a

of fluid

a

pressure is applied to the side of check valve and

does

valve with at connections

replace check valve with

not

open

new

one

Note

leakage

occurs

check valve

replace check

whether

Determine

tion

in

Always inspect

can

120 I

7IG

1 I

100 I 420

i u

yr

I

90 1 280

17 I

80 1 140

I

70 1 000 60

850

0

Z

40

BA3

Fig BR 26 Location of check valve

a

I

I

I

I

570

30 430

I

20 280

vacuum

inHg

a

Master Vac tester

pressure

apply a of 200 mmHg 7 87

to the port of check valve on the

Master Vac side 10 mmHg

39 0

10 140

I

7I

50 710

5

I I

f I

0

Using

in

disconnect hoses

The check valve

110 1 560

2

or

check

valve fiTlit

be removed

now

malfunc

Master Vac

I

y1 I I

I

I

L I 5

to

22

If a pressure drop of inHg is exceeded in

15

20 44

25

I

I I

II I I

y1

I

I I I

30 66

35

I

L I 40

88

45

50

110

55

60 132 BR772

Pedal operating force kg lb

Fig BR 28 Performance BR 15

curves

of Master Vac

Brake

Identify front shell and rear shell clearly so that they may be reassem bled in their original positions from which they were withdrawn Bolts 3

REMOVAL

Referring

System

Figure

to

parts in numerical

BR 29

remove

order enumerated

attached

dashboard

on

not

are

the

same in

pitch Using

4

Master Vac

ST08080000

1 cD

remove

Wrench

rear

shell seal

assembly and disassemble diaphragm plate assembly front shell assembly diaphragm spring and push rod assem bly

2

BA079

FlIf BR 33 Separating diaphragm

2 Using evenly pry

BR17S

Fig BR 29 Removal method of

screwdriver

a

is detached from

Mcuter Vae

as

shown

air silencer retainer until it

diaphragm plate

as

sembly DISASSEMBLY When serve a

the

disassembling Master Vac following instructions

Thoroughly clean mud

Note

ob

dust from

or

Never use

a

hammer to

remove

this retainer since this win be the sure

y of damaging it

Master Vac

b Extreme to

should be taken

care

allow dirt

other

foreign

dust

water

or

not

f Q

any

matter into any

com

select

place

BA076

Fig BR 31 Removing

reor

shell

ponent parts Be

to

sure

before disassembly c

Rear shell seal

assembly

mating joints so that they installed exactly in their original positions Mark

be

may

d Keep

all

disassembled

arranged properly

readily e

clean

a or

so

f

place care

come

1

to

BA322

parts

clean work bench

bly

unless

absolutely

Whenever this is to be removed not to

damage

on

Place

rear

use

it

Master Vac

Use soft jaws

2

Remove clevis and lock

3

Pull out

and

are

valve

withdraw

plunger stop key

silencer

and

plunger

assembly

Use Note

valve plunger stop proceed as follows With key hole facing down lightly push valve operating rod simulta neously while applying vibration to

parts in

nut

To

remove

key properly

shell spacer

vise

retainer

necessary

allow dirt and dust to

Install spacer

tach valve body

Do not disassemble seal assem

Note

care

into contact with these

temporarily

of screw

suitable clean solvent

a

on a not

use

detach bearing

Fig BR 34 Removing air silencer

disassembled

cleaned in

and

that they may

be assembled at any time

all

shown

and seal

parts in alcohol

Mter

as

parts

Clean rubber parts and synthetic resin

off retainer with

Pry driver

a

it

De

guard

rW

BRD7S

Fig BR 32 Removing retainer

ID

Diaphragm plate 1

Clevis

2

Lock

3

Place

Valve body guard

nut

Fig BR 30 Removing

BRD7S rear

hell

on

a

diaphragm plate assembly

clean work bench

phragm

Detach dia

from groove in plate BR 16

as

shown

BA180

Fig BR 35 Pulling out top key

Brake

System

ASSEMBLY AND

ADJUSTMENT 1 Assemble in the

reverse

sequence of

disassembly

SR1S6

Fig BR 41 Rear shell seal BA1Bl

Fig BR 36 Remouing ualue operating rod assembly

Apply

1

a

grease to the

coating of Master Vac sealing surface and lip of

seal and install that seal in with the

use

rear

shell

Install

plunger assembly and diaphragm plate and lightly push plunger stop key in place silencer in

of Master Vac Oil Seal Note

Retainer Drift ST08060000 4

2

Requiring grease place

Diaphragm plate

bakelite

Withdraw reaction disc

Exercise

care

plunger assembly diaphragm plate

not

is

made of

in instaJJing to

damage

BA286

Fig BR 37 Remouing reaction disc

Fig

BR 39 Installing oil seal BROB3

Note

I

Detach flange

Referring

stall

from

front

to

Figure BR 40 in place by properly aligning the pawl of special tool with seal hole Adjustment is cor rect when specified length at A is

Front shell seal shell

assembly

seal

in

obtained

Length

Fig BR 42 Inserting stop key

A

Before installing diaphragm into position apply a thin coating of mica power to it except outer diameter and seating portion with which shell comes 3

into contact

6 7 to 7 Omm

4

0 264 to 0 276 in

Before

place

on

installing reaction disc in diaphragm plate apply a thin

coating of Master Vac

grease

Front shell seal Before installing front as seal shell sembly apply a coating of Master Vac

g

BR287

Fig BR 38 Removing lange

grease to the inner wall

of seal and

front sheU with which seal

comes

into

contact 2

Withdraw front seal assembly Final sssembly

INSPECTION BA1S5

Check poppet assembly for condi tion If it shows evidence of wear or I

damage replace rod

it and valve

Check other component parts for condition If any part shows evidence wear or

new one

damage replace

at

A

operating

assembly

2

of

Apply thin coating ofMaster Vac Fig BR 40 Length

it with a

grease to the outer edges of diaphragm with which rear and front shells come before instaIling dia position 2 Before installing push rod assem bly in place apply a coating of Master Vac grease to the sliding con tact surface of diaphragm plate into

Diaphragm plate I

Apply a thin coating of grease to sliding contact portion on the periphery of plunger assembly the

BR 17

contact

phragm

in

Brake 3

in the

Align marks scribed

shell and front shell Master Vac

Carefully

Wrench

clockwise until it

rear

turn the

ST08080000

Length

INSTALLATION

B

10 0 to 394 0

System

5 10

mID

413 0

to

Install in the

in

reaches notch in

Tightening torque Master cylinder

shell retainer

rl

0 8 to I 1

6

BA290

Fig BR 44 Lelllth

After assembly

push

adjust

Master Vac

m

B

m

8 ft Ib Master Vac

on

vehicle

is be

properly sure

to

air tight test and oper ation test described previously in an

this section

shell

length

the

rod to less than the

value indicated below ment of

at

to

After

conduct

of

to

body

0 8 to 1 kg

installed

reor

sequence of

6 to 8 ft lb

Note

Fig BR 43 Tightenilll

kg

Master Vac to

J

4

reverse

removal

push

specified Length adjust

rod is made at the

tip of Fig BR 45 Adjusting push rod length

push rod

HAND BRAKE CONTENTS HAND BRAKE

Stick lever typ e

REMOVAL

BR 18

INSPECTION

BR 19

BR 19

INSTALLATION

BR 19

HAND BRAKE Stick lever type The hand brake system is of reaction type

a

cable

which actuates

rear

wheel brake shoes

justment

can

be

All the cable ad made

BR 18

by operating

only adjusting

nut at balance lever

Brake

System

k 1

BR663

Fig BR 48 Balance lever Rear cable

Fully release 2

control stem

Remove both

and disconnect

rear

brake drums

rear cable

from toggle

lever 3

Detach spring and spring retainer Remove rear cable from brake

4

disc 1

Control bracket

5

2

Control lever

balance lever bracket

3

Control stem

4

Front cable

5

Balance lever

6

Rear

7

Rear cable LH

Disconnect

6

Detach

cable

rear

cable

clips

from

and

remove

rear cable

cable R H BAS6l

Fig BR 46 Hand brake

linkage

INSPECTION 1

Check control stem

for evidence of wear

or

and ratchet

other damages

REMOVAL

Replace parts which are faulty 2 Replace worn or fatigued springs

Control stem

3

I

Disconnect

3

terminal from hand

Pull out lock pin and colter pin and then remove control stem assem

brake warning switch 2

Remove

nuts

bracket in place

on

bly

control

securing

Check wires for evidence of dis

continuity or other deterioration Re place if necessary 4 Replace faulty warning light and

dash panel

or

switch

S

Check parts at each connection and if found deformed or damaged

y

replace

J

i1 b

INSTALLATION Install hand brake

I

I

1

II i I

assembly in the

sequence of removal by closely observing the following instructions reverse

l

When

installing apply

a

coating

of grease to sliding contact surfaces BR773

Fig BR 47 Control stem

Make 2

Front cable

Sure

that each sliding part func

lions smoothly

Upon completion of installation

of hand brake

Fully release control stem Loosen adjusting nut at

2

5

balance

lever 3

Disconnect front cable from

Remove retainer

guide bushing

LH

con

6

rear

cables

R H and

from balance lever brackets See

Figure

trollever 4

Disconnect

48 BR

Remove

at cable

7

lions ment

balance

lever

brackets

from crossmember

spring

assembly adjust the referring to the instruc described under topic Adjust

entire system

Detach front cable

front cable rearward

BR 19

3

Make

sure

that each cable is not

interfered with by any

clip

and pull

Do

not

cables

apply

an

adjacent

undue

parts

stress

to

Brake

System

SERVICE DATA AND SPECIFICATIONS Brake

Brake

pedal mOl

in

148 S 83

mOl

in

I to 3

Full stroke at pedal pad

mOl

in

134 to 140 5 28 to

Depressed height

mm

in

Free

height

Free

play

at

pedal pad

0 04 to 0 12

43 to 49

169

51 S

to 193

adjustment notches Front

12

Rear

12

Master

cylinder

Inner diameter

mm

in

19 0S

Piston to cylinder deaJance

mm

in

O IS 0 OOS9

mOl

in

4 6 152

Yo

Master Vac

Diaphragm diameter Maximum

vacuum

leakage after 15 sec

mmHg inHg

2S 0 98

Shell seal

depth

A

mOl

in

6 7 to 7 0 0 264 to 0 276

Push rod

length

B

mOl

in

10 0 to

5 0 394 to 0 413 10

Front drum brake Uni

Type Wheel cylinder inner diameter

in

I9 0S 45

Lining Width

Lining

mm

x

Thickness

mOl x

in

mm

in

Yo 4 x 244 5

x

77 1

Length

wear limit

servo

x

0 177

x

9 61

1 0 0 039

Rear drum brake Duo servo

Type Wheel cylinder inner diameter

mOl

in

19 0S

mm

in

254 0 10

mOl

in

2SS

mOl

in

0 02 0 0008 maximum

Yo

Brake drum

Inner diameter

Repair

limit of thickness

Inside runout

S 10 06

PaJking brake Stick type

Type in

Stroke

mm

Adjuster sliding resistance

kg lb

80 to 100 S to 12

BR 20

lS 3

to 3 94

11 to 26

Brake

System

Tightening torque Master cylinder to Master Vac

kg

m

ft Ib

0 8 to l 6 to 8

Brake tube flare nut

kg

m

ft Ib

IS to 18

Brake hose connector

kg

m

ft lb

1 8 to 2 1

Air bleeder valve

kg m ft lb

Fulcrum pin of brake pedal

kg

m

ft Ib

2 to 1 1 5 9 to II

Connector and clip

kg

m

ft lb

0 35 to

kg

m

ft Ib

0 8 to l 6

kg

m

ft Ib

12 to 1 5 9 to II

kg

m

ft Ib

0 8 to l 6 to 8

kg

m

ft Ib

S 4 to 6 6

kg

m

ft Ib

5 to 1 8 II to 13 1

kg

m

ft lb

1 9 to

Front

kg

m

ft Ib

4 2 to S O

30 to 36

Rear

kg

m

ft Ib

S 4 to 6 4

39 to 46

kg

m

ft lb

0 8 to l 6 to 8

kg

m

ft lb

0 8 to 1 6

kg

m

ft Ib

16 to 2 2

kg

m

ft Ib

1 9 to

3 way connector

fIXing

fIXing

bolt

bolt

on rear axle case

Brake

pedal stopper lock

N LS V to

nut

body

II

to 13

13 to IS

0 7 to 0 9 S to 7

4S O

5 to 2 to

8

Wheel cylinder mounting nut Front

Rear connector bolt

Wheel cylinder

Brake disc Back

plate

5 2

39 to 48

14

to 18

nut

Master Vac Master Vac to

Flange

to

shell

body

cover

Operating rod lock Push rod

nut

adjusting

nut

nut

nut

BR 21

to

8

12 to 16

4 14 2

to

17

3

Brake

System

TROUBLE DIAGNOSES AND CORRECTIONS Condition Excessive

pedal

travel

Probable

Low

brake

1uid

cylinder

reservoir

Leakage

in master

Corrective action

cause

level

master

empty

or

Fill and bleed

necessary

Air in system

Bleed system

adjustment

Low 1uid level in master

cylinder

Correct

brake adjustment

as

hole

clogged

Swollen hose due to deterioration

Inspect

for

leakage

necessary

shoe

Adjust aut

vent

clearance

operation

Top with 1uid and inspect

Air in system

Reservoir filler cap

connec

and bleed system

shoe to drum

Adjust

autoadjuster

Faulty

lines

Overhaul master cylinder

cylinder

Replace check valve

brake

Test for source

by examining all tions and wheel cylinder

Deteriorated check valve

Faulty

Spongy pedal

as

of leakage

to

drum

clearance

Inspect

adjuster operation

Clean and bleed system use

or

of

Replace hose and bleed system

poor quality hose Distorted or

Soft

or

swollen

Use of

Poor braking effect

brake shoes

excessively

or

worn


cracked brake drum

caliper

brake

a

seals

Drain hydraulic system and replace all seals

1uid with too low

boiling

Replace

with

specified

point

system

Fluid leakage in brake lines

Check master

Low

brake

1uid

level

cylinder pIpIng cylinder for leaks and repair empty

or

master

Air in brake lines

Excessive shoe

Fill and bleed

as

oil

ta

mud

drum

clearance

water

or

Deterioration of linings Local fit of linings

or

or

wheel

necessary

Adjust

linings or pads

on

Master cylinder condition

or

pads

Clean brake mechanism and check for

Shave

wheel cylinders in poor

at

or

replace

Replace

worn

Binding mechanical linkage

Replace linings

Replace

pads

Linings or pads excessively

brake

pedal

Repair

or

Free up

replace

as

required

and shoes

Clogged

and

Bleed system

of problem

Brakes drag

brake 1uid and bleed

reservoir

cylinder

Grease

flush with alcohol

brake lines

Incorrect

adjustment

Improper

shoe

t

Check and clean of wheel

bearings

drum clearance

Adjust

or

repair

Adjust

Weak shoe return springs

Replace

No free travel in brake shoe return

Adjust pedal height

BR 22

or

pads

cause

Brake

Probable

Condition chatters

Brake

required

Grind

Loose or bent brake disc

Tighten support plate bolts torque or replace plate

Grease

squeals

Corrective action

cause

Groove or out of round brake drum

Distorted brake shoes

Brake

System

Dirty

or

as

to

specified

necessary

Replace linings

brake fluid on linings

compressed

with

assembly

Blowout

scored brake drums

or

replace

as

Replace

pads

or

or

air

or

refinish drum Distorted brake shoes Weak or

or

Replace faulty unit if faulty

Replace

spring

ground lining to doesn t replace linings

contaminated brake lining

Pedal pulsates

Out of round

Brakes fade

Brake fluid has Use of

bent support plate

broken brake shoe retaining spring

or

return

Glazed

or

Cam

Turn drum

off center drum

or

too

low

or

brake

replace

as

linings

are

If it

glaze

necessary

approved

Drain and fill system with

boiling point

improper linings

or

eliminate

fluid

Replace linings

contaminated Brake drums

are

out of round master cylinder and

Hydraulic connections wheel cylinders are corroded Bleed

Brakes

drag

screw

or

replace

Repair

as

necessary

Close

or

necessary

as

damaged

is open

Pedal linkage is binding ment is too

or

Repair

push

rod

adjust

screw

Lubricate

and bleed system

linkage

check

pedal

return

for condition and adjust push rod

long

spring

as neces

sary

Master

cylinder compensator part

is

ob

Blowout foreign

structed

air

Seized master cylinder piston

Disassemble

matter

master

with

cylinder

compressed and

replace

piston Bleed system Clean and repair

Poor shoe condition

Poor wheel

or

replace

Deformation of piston cups

Replace

Hand brake will not

Check and repair

Clogged Unbalanced brakes

Repair

cylinder condition

master

Improper

return

cylinder

return

port

Clean

Inflate

tire inflation

Improper adjustment of shoe

to drum clear

to

correct pressure

Readjust

anee

Grease

oil

mud

or

water on

linings or pads

Clean brake mechanism and check for of problem Clean

Mud in brake drum Deterioration of linings Excessive

wear

or

of linings

Replace

pads

or

pads

BR 23

Replace

Replace linings

or

pads

cause

Brake

Condition

Probable Wheel Poor

Corrective action

cause

in poor condition

Repair

condition of brake shoe

Adjust

cylinder

sliding

System

Looseness of cylinder body

or

back plate

Fasten

or

replace

or

replace

securing bolts Scored

or

out

of round drums

Recondition

or

replace

brake

drum

as

reo

Check for improper lining contact

quired

with drum and grind lining if necessary

Sticking

wheel

cylinder

Deformation of back

Recondition or

cups

plate

replace cylinder

Replace

Incorrect adjustment of wheel bearings

Adjust

Incorrect adjustment of wheel alignment

Adjust

Looseness of leaf spring securing U bolts

Tighten

Faulty

Replace

N LS V

or

replace

or

replace

Pedal yields under

Deteriorated check valve

Replace

slight pressure

Ex ternalleaks

Check master cylinder

Leakage

on

master

check valve and bleed system

piping cylinder for leaks and repair cylinder

Overhaul master cylinder

BR 24

and wheel

Brake

System


Tool number

Description

No

tool

1

Unit

name

GG943 10000 Flare nut

torque wrench

This tool is used to A built in

tighten

torque limiting

and

untighten brake provided to

wrench is

mOl

in

tube flared nut assure

For

Reference

use

page or

on

All

Figure Page

No

BR 8

models

torque

accuracy

SE227

2

ST08080000 Master V ac

This tool is used to remove bolt with the

opening

rear

shell after aligning

rear shell

stud

All

Fig

BR 3l

Fig

BR 39

models

in this tool

wrench

SE073

3

ST08060000

This tool is used when

rear shell

seal is driven into position

All models

Master Vac

oil seal retainer drift

Note

Make

sure

tool touches

that this tool is

pushed in until

rear

guide

of this

rear shell

SEll5

BR 25

SECTION WT

WHEEL AND TIRE DATSUN PICK UP MODEL 620 SERIES

WHEEL AND TIRE



LTD JAPAN

WI

2

WI 5

Wheel and Tire

WHEEL AND TIRE CONTENTS DESCRIPTION

WT2

TIRE

MAINTENANCE AND SERVICE

WT 2

CHANGING TIRE

ROTATION

WT3 WT3

TIRE INFLATION

WT2

INSPECTION

WTA

TIRE

WT2

WHEEL

WTA

WHEEL REPAIR

WT 2

WHEEL AND TIRE

WEAR

WT 2

REPAIR

BALANCE

DESCRIPTION The 620 series models

WT 4

TIRE REPAIR

equipped

are

with 4lV 14 wheels with 25

mOl

In

0 98

order

to

inspect

soapy solution to tire

in offset All tires are tubeless

leak

a

or

tire

and wheei in the water after to specified pressure spection for leaks should tire

Tire size

out

Model

Tire size

All models

apply

submerge

6 00 I 4 6PR

along

Wheel size

Tubeless

around the valve the tread

inflating Special in be carried

wheel rim and

Exercise

care

to bead

and rim where leakage occurs Wipe out water from area which leaks air

4UJ 14

bubbles and then mark the place with chalk

Tire pressure

Unit

2

kgl em

psi

After removing the materials which caused puncture

Vehicle speed km h

MPH

Under

h km

100 Model

seal the point When repairing the puncture use the tire repair kits which are furnished from

Over 100 km h

60 MPH

60 MPH

tire dealers

provided Front

15

Rear

175

21

18

26

following

other damage 2 25

In

case

that

a

puncture becomes large

Unloaded 25

the instructions

with the kits

32

on

or there is any the tire fabric repair

must be carried out

All models

by

authorized tire

dealers Front

15

21

Rear

3 0

42

18 26

Loaded 15 3

4S

WHEEL REPAIR Note

Tire inflation pressures should

be measured when tires

are

cold

underinflation promotes wear ter tread or shouider of tire If aU

tires

are

at

cen

inspected frequently

and maintained correct tire pressure is

possible

it

detect sharp material in

to

the tread Also the above check avoids abnormal

MAINTENANCE AND SERVICE

serious

If tires indicate abnormal

problem uneven

which invites

wear

the

wear

cause

Inspect bend

or

The

the wheel

rim

flange

for

dents

flange

should be cleaned by

a

wire brush when rust is found on the

flange

Furthermore

pitting with

a

occurs on

if

the rim

excessive

eliminate it

file

or

of problem

should be detected and eliminated TIRE INFLATION

After

inflating

tires

leakage

in valve

should be checked Without valve caps Correct tire

portant comfort sound

longer

pressure

to ease of

to

This a

is

steering

also

very

reduces

minimum

im

and

riding driving

resulting

tire life that is overinflation

in or

leakage water

will

resulting

cordingly checked

firmly

occur

due

dirt and

in underinflation

whenever tire be

to

sure

to

pressure

tighten valve

by hand

Ac is

caps

WEAR

Missilgnment When excessive

front

toe in

tires scrape wear

WT 2

the

or

wheels

align

in

toe out condition

the tread rubber off The

of tread appears feathered edge

Wheel and Tire and on the other hand

Center

wear

This wear is caused

by overinflation value

specified

at the

kept

Tire tread Tread

on

driving former

or

camber

on

pension

two

Underinflation

common

are

occurs

wear

I 0E

round brake drum

Toe in

wear

correct the above

CHANGING TIRE To i

1 I

1

1

Overinllation

wear

wear

1

unevenly

and

become

The spare lire has from 4 tires

in tire noise which is attributed to rear

Right front

axle gears bearing etc Meanwhile the

I

tend

of

because

to

wear

it

is

Right

necessary

to

equalize rotate

tires

rear

is necessary to

@

Spare

It

cap

and temporarily to loosen wheel To

jack

side frame rear

front

Left

rear

up front

remove

jacked

about S20 mOl

brake

up

place jack

of front axle center

ing parking Left

wheel

2

3

wear

peri

tire

different brand

r

J

tire

a

spare

the vehicle

x

front

wheel to

on

nuts before vehicle is

unevenly

wear

improperly aligned

Accordingly

installing lighten a lifting up and lock

Fig WT 5 Removing

unbalanced according to running dis tance Uneven tire wear often results

jack

WT007

wear

TIRE ROTATION

tires

insert

I

t

Uneven

When

little strong after

I

wear

a

and then turn it counter

guide

clockwise

using

observe the

To remove spare tire

rod to

Fig WT 1 A bnormal tire

wear

tire with wheel

change

in the safe manner

jack following procedures

Ii

Underinnation

indicator

faulty parts

J

nf I

wear

other mechani

I

toe out

or

Fig WT 4 Tread

out of

wheel

or

WH024

cal conditions To repair this abnormal

both sides of treads

d

by incorrect malfunctioning sus

unbalanced

I

front

indicator

is caused

caster

or

I

Tires

wear

c

Uneven

by under

wheel camber

high speed general the

In

causes wear

may be caused

incorrect

continuous curves

one

Uneven

wear

inflation

causes

side of treads For

curves

Shoulder The

camber

cornering tread wear the driver must down on operate vehicle slowing

of the tire The inflation pressure must be

only

on

under

5 in at 20 after

apply

and blocking

rear

wheels

odically All the tires including the spare tire are

of the

same

Right front

Right

Left

1

I

@

The tires wear

Spare

J

in

wear

tread

1

g 1

provided with tread at six places around indicating

depth

When

1 6 mm the

and then the marks appear

place them

rear

WT 2 Tire rotation

are

indicator

tire circumference

t Left

Fig

emergency only

Fig WT 3 Tire rotation 2

rear

1

front

pare

in an

type

1 14

t

tire should be used

The

with new ones See

tires re

Figure

WT012

Fig WT 6 Jacking up front side

WT 4

WT3

Wheel and Tire 4

To

rear

axle

jack

case

close

under

place jack

rear

up

the side of rear

to

spring after applying parking brake and blocking front wheels

Proper tire balance is necessary when driving the vehicle at high speeds Consequently the wheel and tire assembly should be properly re balanced

whenever

is

puncture

re

Thoroughly

remove

oxidized rubber

rust

rim with wire brush

emery cloth or

Use

dial gauge to wheel rim for lateral out run paper

dust

sand from wheel

or

examine

paired The comes uneven

wheel and

tire

of

according

Less

to

run Qut

tltan

limit

5mOl 1

0 059

il total

indicator

Severe acceleration

wear

reading

fast cornering is the

or

wear

Lateral

assembly be

of ba1ance

out

and braking cause

tire

tire

on

resulting

in

unbalance of tire and wheel assembly The as

symptom ofunbalance appears tramp vehicle shake and steering

malfunction WH077

To correct Fig WT 7 Jacking up

S

Remove

wheel

rear

side

and wheel

nuts

To

177 gr cm wheel

install

reverse

the

nuts

fashion to 8 0 to 9 0 kg ft Ib Note

Nerer

while it is

get

in

10 gr

3S O

5 in 2

oz

at rim circumferences

oz

WTOO5

m

use

at

S8 to 6S

only by the

fety stands

S8

Fig WT B Whetl rim

10 to 60 gr

cross criss

under the vehicle

supported

jack Always

proper

Balance weight

above

steps Tighten wheel

use

Maximum allowable unbalance

from drum 6

unbalance

wheel balancer

to

support the side member of body construction when you must get

Note

Be

of rim

10 gr

as

weights

12 2

to

0 3S

oz

place the

to

sure

balance

3S O

on

shown in

00 not put more than two on each side

out check

points

intervat

correct

the inner

Figure

run

oz

edge

S WT

Note

weights

In

not to

replacing tire t e extra care damage tire bead rim flange

and bead seat

beneath the vehicle

Do not use tire irons to force beads

away from wheel rim flange that is always use tire replacement device whenever tire is removed WHEEL AND TIRE

INSPECTION

2

In

WHEEL BALANCE The wheel arid tire

asSembly

order

to

ensure

steering condition should

be kept balanced statically and dynam ically

tire life proceed

as

as

well

satisfactory as

maximum

follows

Check wheel rim for rust distor tion cracks or other faults

4 WT

Discard when any of the follow

ing problems occur 1

Broken

2

Ply

3

Cracked

etc

o

or

damaged

bead wire

treairsepanitiori or

damaged

side

wall

Wheel and Tire


Condition

Wheel wobbles

Probable

Corrective action

cause

Improper

tire pressure

Measure and adjust

Damaged

tire or distorted wheel rim

Repair or replace

Unbalanced wheel

Balance

Loose wheel nuts

Tighten

Worn

damaged

or

wheel bearing

or

excessive

Correct play

or

replace wheel bearing

play of wheel bearing Improper front wheel alignment

Align

Worn or damaged ball joint Excessive

Replace

linkage play

steering

or

worn

Adjust

Or

replace

steering linkage Loose steering linkage connection

Tighten worn

nuts

to

rated torque

Broken suspension spring

Replace

Damaged shock absorber

Replace

Unevenly or

Improper

tire rotation

Conduct tire rotation

excessively

Improper

tire pressure

Measure and adjust

worn

tire

Unbalanced wheel

Balance

Improperly adjusted

brake

or

periodically

Adjust Align

Excessively

Repair replace

distorted

replace

replace

Improper wheel alignment or

or

parts if any

improperly installed

or

if necessary reinstall

suspension link

High speed on Sudden

start

due to

and

rapid acceleration plication Tire

squeals

Reduce

curves

improper speed or improper brake ap

speed

Follow correct and proper

Improper

tire pressure

Measure and

Improper

front wheel alignment

Align

Distorted knuckle

or

suspension link

WT 5

Repair

or

adjust

replace

driving

manner

SERVICE MANUA L

4

SECTION ST

STEERING SYSTEM


I NISSAN I NI55AN MOTOR CO TOKYO

LTD JAPAN

STEERING

ST

2


ST

8

TROUBLE DIAGNOSES AND CORRECTION

ST

9

SPECIAL TOOLS

ST 10

STEERING SYSTEM

STEERING CONTENTS DESCRIPTION

ST 2

STEERING GEAR

ST 3

al and installation Remo

Disassembly

and

The

other end of the

linked to

steering

gear

used

model series vehicles is

circulating type

e

on

this

same

re

This steering gear

is

designed especially for easy operation and high durability The steering linkage is of

design of which gear to one end of the

arm is

adjustable

a

relay

connected cross rod

the

idler

cross

arm

rod is

on

safely

arm

and idler

arms

right

arm

left andlor

the idler

right

wheel

moves

rotation is converted

gear arm motion operates the side rod on the same side At the same time

to the

sides even

arm

is moved

through

the

rod and the opposite side rod is also moved

if the

cross

vertical

Steering column shaft Steering column jacket 3 Steering wheel 4 Column clamp

10

Side rod

S

Post

11

Steering

6

Steering

1

7

Cross rod

2

8

Cross rod socket

9

Idler

llmet gro gear

be

to gear arm motion in proportion to the gear ratio by the steering gear The

and left hand

With this construction

can

maintained

Steering wheel

the

opposite side of the steering gear The two side rods serve to connect the both knuckle

6 ST ST 7

ly and independently steering

connecting

with the side member located

steering gear

ST 6

Inspection and repair

4 ST

assembly

ST 5

LINKAGE


ST 3

DESCRIPTION The

Inspection and repair STEERING

arm

assembly

gear

assembly

arm

ST528

Fig ST I Structural sr 2

u

w

of

l teeriTl

tem

STEERING SYSTEM STEERING GEAR

A

i

p u

I 1

jj @

@

@l

ST199

Sector shaft adjusting

J

9

2

3

Filler plug Sector shaft

Worm bearing adjusting shim Column jacket

Sector shaft adjusting screw shim

11

5

Gear housing Sector shaft

13

8

12

14

Oil l

7

assembly

10 cover

4

6

Worm

ball nut assembly

screw

15

Steering

column

shaft

Column jacket bushing

ring Worm bearing

Gear housing bushing

Fig ST 2 Sectional view of steering gear


3

Remove

Removal

nut

Steering after

wheel

steering

Wheel Puller

backing

with

ST27I80001

6

Remove

column

clamp

fixing

bolts

off steering wheel fIXing @

c


I

from the terminal Remove horn

2

pad by unscrewing

I

two bolts from the rear side of steering

c

wheel bar Note 0

Be sure on

to

punch

f I

mark with

1

the top of steering column

shaft i

I

1 T201

Fig ST 5 Removing column clamp Fig ST 4 Removing teering wheel

Note

Be

special

sure

not

to

hammer the 7

tool while removing

Remove four bolts securing steer

ing post grommet Remove upper and lower steering column shell covers 4

S

Fig

ST 3 R

moving

horn pad

Remove

turn

signal

switch

as

arm

with the

ST2902000I

sembly ST3

to dash

panel

Remove nut securing gear arm to sector shaft and then withdraw gear 8

use

of Pitman Arm Puller

STEERING SYSTEM and

Disassembly assembly

9

Disassembly I

Drain oil in

gear

ST202

Fig ST 6 Withdrawing gear Note

Before

arm

and be

screw

few turns

a

Remove

so

from

the

rear

Do not

remove sector shaft bushing housing If necessary replace as a gea2 nousing assembly

from

b Do not disassemble ball nut and un

geir

worm

screwing four fixing bolts

them with

If necessary

replace

new ones as a worm

gear

assembly

can

three

bolts securing steering gear housing to frame 10 Withdraw steering gear assembly toward engine compartment 9

a

coun

by

cover

O ring

Notes

easily in their original posi assembly

housing replaced

tions at

that they

gear

on arm

Remove

of column jacket and discard it Remove column jacket bushing

a

terclockwise Remove sector shaft

removing steering

scribe match marks

ann

adjusting

and discard it

cover

Loosen lock nut and turn sector

shaft

housing

housing in

sector shaft oil seal from

out

10 11

steering

by unscrewing fIller plug 2 Place steering gear assembly vise securely 3

Pry

gear

rn

ST203

Fig

Installation Install steering gear assembly in the reverse order of removal observing the

following

instructions

I When installing steering gear housing securing bolts insert two bolts through gear housing to frame

2

When

align four tions with

installing steering grooves of gear

ST 7

4 a

Remouing

sector haft

Turn sector shaft

adjusting pull

few turns clockwise and

shaft

cover

from gear

together with

couer

screw

sector shaft

housing

Assembly Apply

and

adjustment

recommended gear oil to all

disassembled parts

gear arm

arm

Fig ST 9 Removing steering worm assem bly

sector

1

serra

Fit

column

column jacket in

four projections of sector

jacket bushing

to

place

shaft serrations 3

Tightening torque

ST204

Steering gear housing 4 6 to 3 kg m 33 to 38 ft lb S Gear

kg

m

adhesive to

fitting apply

exterior and grease to in

terior 2

S

51 to 54 ft Ib

6

With front wheels set in a

straight

that punch mark on the upper end surface of steering column shaft is at the center upper side

Separate

screw

ahead position make

sure

in

its

installing

portion S

bushing

Fig ST B PuUing out ector haft

94 to 108 ft lb

Steering wheel 7 0 to 7 S kg m

of the

When

arm

13 to IS

4

Note

7

Remove steering

worm

Fill the space between

to gear unscrew

3

worm

worm

bearing adjusting

housing

shims

worm

shims

4

from

assembly and column jacket

steering wheel

may be

run

down to the

worm

end

worm

suddenly

end to

If the

the ends of ball guides

damaged ST 4

worm

housing

assembly

in

together with

Install

column

jacket

with O ring and

on

worm

gear

bearing

Be sure to install thicker shims to

Be careful not to allow ball nut

ball nut rotates

in gear

bearings

bearings and

gear

sector

housing

Place steering

position

assembly

new

shaft oil seal lips with grease and fit it

from gear housing 8 Detach worm

to

smoothly

adjusting

and shim from cover

installing steering wheel apply grease to sliding parts 6 After installing make sure that turns

shaft

Remove jacket tube by ing three fixing bolts

Note

When

sector

the gear

housing

side

Standard shim thickness 5 mOl 0 OS9 in 1

Tightening torque 5 to 2 S 1

kg m

11 to 18 ft Ib

STEERING SYSTEM Available

worm

8

bearing adjusting

shim

Install sector shaft Be

housing

cover

each face of sector shaft No

Thickness

I

0 762

2

0 2S4 0 0100

mOl

in

when installing 9

0 0300

3

0 127

0 0050

4

O OSO

0 0020

Pull sector shaft toward

bearing preload with Preload Gauge ST3127S000 by selecting suitable bearing shims so that the initial turning torque of steering column is the Initial

worm

specified

value of

turning torque

steering

column shaft

shaft

kg

cover

11

m

worm

4 0 to 6 0

Used

bearing

kg

em

S6 to 83 in oz

4 to 2

61 in oz

into the

screw

adjusting

shaped groove at the sector shaft head and adjust the end play between T

sector shaft and

adjusting

it is within 0 01 to 0 03 to

in

0 0012

screw

mm

5 2

to 18 ft Ib

Push sector shaft against ball nut

gear

by gradually

Sector shaft 1

Check gear tooth surface for pit ting burrs cracks or any other dam age and replace if faulty 2

Check sector shaft for distortion

of its

serration

this

and if necessary re be sure to check

place housing for deformation case

gear

turning adjusting

clockwise until sector shaft gear lightly meshes with ball nut gear and

temporarily

screw

with lock

12

Install gear

and

move

sure

or

nut

Adjust

to sector shaft

arm

smoothly

mOl

column shaft

assembly Inspect the ball nut gear tooth surface and replace if pitting burrs wear or any other damage is found 2 Ball nut must rotate smootWy on worm

arm

screw

neu

by turning that

so

movement of the gear arm

less than 0 1

times

and make

the backlash at the

adjusting

Steering 1

arm

sector shaft several

that it turns

out

adjusting

secure

in

If found too

gear

should be

bly

replaced

top end

Move

is

until

0 0004

ball nut

to

its

entire

Note

In

mOl

57S 1

0 0620

I

2

550 1

0 0610

wear

3

525 1

0 0600

4

IS00

0 OS91

S

1 475

0 0581

excessive

6

I 4S0

0 0571

3

ST207

Fig ST 10 Mea uring backlash

adjusting

screw

approxi

1 8 to 1 6 turn clockwise and

Rotate ball nut by hand until it is

in the center of its trovel sector screw

shaft

together

in gear

housing

then install

with

adjusting

ensuring that

the center gear of sector shaft engages with that ofball nut

mately then retighten lock kg m 22 to 29 ft Ib

or

freely

may

be

with a new one as

be

inspection ball nut

e

careful

guide

tube

bushings

worm

any other

bearings if pitting damage is found on

them 2

Repiace column bushing which is worn

deformed

or

If sector shaft are

found

bushings

worn or

replace as an assembly and bushing

in gear

damaged

of gear

housing

nut to 3 0 to 4 0

Fill recommended gear oil ap X U S pI 33 0 liter proximately IS

gear assembly pt through the filler hole and install filler

X Imper

and

Replace

housing

7

this

Bearings

in

Thickness

above

move

no

assembly

stroke

not to dama

shim

Turn

either end of

weight In the

own

if ball nut does

test over

14

fol

gear and gradually stand steer ing column shaft assembly until ball nut moves downward on worm gear under

by choosing suitable

0

as

worm

0 004 in

Available sector shaft adjusting

I

assem

lows

damaged Replace an assembly

No

tight Check

the

adjusting shims

screw

disassembled

screw

tral position of gear Insert

screw

sector

II

13

6

repair

the

in solvent and check for condi

parts

In

from the side of gear

bearing 4 kg em 33 to

worm

cover

bolts to lS to

fixing

Wash

cover

0 08 to

mOl

counterclockwise

then New

3

to

by turning adjusting and tighten

in

all

clean

screw coun

gear housing and then temporarily secure it with its fixing bolts

2

and

Inspection tions

to

12 0

the

packing

terclockwise attach sector shaft

approximately Adjust

cover

cover

By turning adjusting

10

5

to gear to

apply sealant

to

sure

into

Oil seal O

gasket

ring Do not

removed

ST 5

reuse

above parts which are

once

Be sure to

reassembly

plug

and

use

new

parts

at each

STEERING SYSTEM STEERING LINKAGE

Cross rod both side rods and the

6

adjacent parts

can

Removal and

the vehicle as an

installation

7

I

Jack up the

2

on

the

front of vehicle and

pins

To

from knuckle

side

arms

rod

insert Ball Joint

the

following

Ball stud

must be done without this

baIl stud

Must

head

arm

the

on

in the reo

kg

4

kg

Ic

ann

Remove riut securing gear

S

See

Figure

Remove idler

arm

rod

length

8 to 10

a

side

toe in and

31 20

in

steering angle

ing angle adjustments Ie described

in

Section FA

mm

0 04 to 0 20 in

Steering angle

m

Inner wheel Outer wheel

Cross rod adjust bar lock nut

ball

3S030 30030

to to

36030 31030

kg m

72

f

fL

Cro

2

3

Side rod Cross rod socket

4

Idler

5

mm

20 31 in

rod

1

s

assembly Gear housing arm

Mter adjustment of toe in be sure that dimension A at both ends of cross rod is not less than 20 nun 0 79 in ST210

assembly

Fig ST 13 Adjusting cross rod assembly

armOD

sector shaft and remove gear arm with the of Pitman Arm Puller use

ST29020001

cross

m

assembly

in this operation

Ball joints

Adjust

1 to 5

S S to 10 0

5t6

ST 11

Standard

observing

23 to 27 ft lb

2

Fig

be the

notes

3 2 to 3 7

not

socket of side rod and side rod with hammer and so

joints

at

40 to 72 ft lb

Idler

hammer backing up the opposite side a large hammer and bail stud the

done

Toe in

of it with

strike

be

rod

both end of cross rod assembly

Tightening torque

tool strike the knuckle arm boss with

is freed from knuckle arm

linkage

sequence of removal

verse

and separate them by striking the top of this tool with a hammer If this

a

should

Adjustment

cross

The procedures of toe in and steer

Install steering

ball studs

Remover HT72520000 between them

operation

adjust

tween the centers of ball

3

to knuckle

Assembly

detach

separated length correctly

516 rom

arms

3

are

Then separate the ball joints of

and nuts fas

rod ball stud

tening side

When cross rod sockets and cross

rod

stands

safety

Remove cotter

assembly

steering linkage assembly following the procedure for removal ofthe side rods ball joints at knuckle arm sides

Removal

support it

then be freed from

2

Idler

ann

assembly

ST 6

assembly from

frame by backing off fixing bolt and

@

nut

A

1

Idler

2

Collar

3

idler body Plain bushing

4

Screw bushing

body welded to

T529

Ffa

ST 12 Removing idler

Fig

ann

ST 6

ST 14 Sectional

W

of idler

arm

sembly as

SYSTEM 1

Apply recommended grease to bushing interior plain bushing interior dust seal inside and bushing sliding surface of idler ann

nipple

screw

Screw

and reinstall filler

In

make A

is

installing

sure

plug

arm

S 42S to

Before

installing idler arm assem iller plug with grease bly replace f nipple and apply recommended grease to idler ann through this grease nipple

See Figure ST 14 Furthermore be washers correctly

A

I

I

I

J

I

FIODt

Idler sure

to

1

When ball stud is

play

is too excessive

socket 2

replace

side rod with

or

When

defonned

dust be

cover

sure

worn or

to

axial

cross rod

a new one

is

broken

replace

with

or a

new one

Axial end play

0 1 to

5 mm 0

0004 to 0 020 in Initial

swing torque

S to 15

cm kg

70 to 209

oz in

until grease is forced

Figure

arm

3B8embly

Remove old grease and dirt and check idler ann assembly for wear

install ST IS

STERING

CrOBS rod side rod and

Check them for

bending damage

and crack and replace

as

necessary

Inspecting steering system the vehicle which

comes

on

into

collision is very important vehicle When the vehicle

Steering system for driving

L6

comes

a

into

collision

especially

the

front of the vehicle is damaged special inspection should be done for the

following Spring

washer

matters

3

Plain washer

If any component parts of steering system is found to be damaged re

4

Weld nut

place

5

Self locking nut

1

Frame

them with

new ones

Steering angles correctness Inspect side rods and cross rod for

bend and sector shaft for distortion ST212

2

Level of steering wheel bar

the front wheels in Ifits deflection is

70 to 209

cm kg oz in

a

with

straight ahead

position 90 degrees the bend

more or

than about

distortion of

sector shaft and column shaft can be seen

3

Noise during operation of steering

wheel

Inspect

column shaft

and jacket

tube for bend Smooth

4

operation

of

steering

wheel

Inspect ball nut

gear for breakage for dint and column

sector

screw

shaft for bend S

Gear

6

Gear housing

ST213

ST 7

arm

gear

Initial swing torque 5 to 15

Ball joint

nipple

in

Fig ST 15 Locations of washers

Inspection and repair

grease

deformation and damage

I

8

nipple

mm

until grease is forced out at the lower end of the dust seal lip Remove grease

I

grease

out at the grease vent hole

504 S

See

renew

remove grease cap and apply recom mended grease to ball joint through

adjusted correctly 137 8 to 139 8

To

sary

assembly

that the standard dimension

87 ft lb

kg m

idler

Standard dimension

bushing tightening torque 12

2

3

In

breakage breakage addition inspect gear housing arm

f IXing bolts for looseness 7

Distortion of sector shaft

tion 8

Sector gear

breakage

serra

STEERING SYSTEM 9

Column

shaft breakage

on

the

10

welded section In

Deformation

of body construc

tion and frame

addition

inspect column shaft

Inspect

steering system

on

the body construe

tion and frame for deformation or any

the installation portion of

other faulty conditions

for scratch

SERVICE DATA AND SPECIFICATIONS SPECIFICAnONS

Gear type

Recirculating

Gear ratio

ball type

I

19 8

SERVICE DATA

Standard thickness of worm

adjusting

bearing

shims

in

mOl

5 0 OS9 1

Initial turning torque of steering column New worm

bearing

Used worm

bearing

kg kg

em

in lb

4 0 to 6 0

em

in lb

2 4 to

4

5 to S 2 3

2 1 to 3 8

End clearance of sector shaft

adjusting

screw

Backlash at the gear

arm

top end

Oil capacity Bail

in

om to 0 03 0 0004 to 0 0012

rom

in

o to 0 1

t U S pt Impel pt

joint axial

Standard

rom

cross

end play

rom

in

rod length

rom

in

Toe in

0 33

0 to 0 004

J X

0 1 to 0 5 0 004 to 0020 516

in

31 20

I to S

004 to 0 20

Inner wheel

35030

to 36030

Outer wheel

30030 to 31030

rom

Steering arigle

Tightening torque Unit

Steering column jacket Sector shaft

to

gear

housing

kg

m

1 5 to 2 S

cover

IS to 2 S

ft lb II to 18

II

to 18

Sector shaft lock nut

3 0 to 4 0

22 to 29

Gear

housing

4 6 to

33 to 38

Gear

arm

Steering

wheel

Bail studs of cross rod

3 5

13 to IS

94 to 108

7 to 7 S

SI to S4

S S to 10 0

40 to 72

Ball studs ofside roo Knuckle Gear

or

arm

idler

side arm

side

ST 8

S S to 10 0

40 to 72

5 to 10 0 S

40 to 72

STEERING SYSTEM


Condition

Steering wheel heavily

Steering wheel but sluggishly

moves

Corrective action

cause

Wheel alignment out of specifications

or

air

Align or inflate

tires to correct pressure

pressure in tires too low

turns

Steering linkage

out of adjustment

Steering column

out of alignment

Wheels out of alignment

or

air pressure in

see

relative topic under Front

Repair Repair

or

inflate tires to correct air pressure

tires too low

Replace and Suspension

Damaged steering linkage

Vehicle pulls to

Adjust and Suspension

one

Wheels

out

of proper

see

relative topic under Front

Align

alignment

side

Wheel bearing out of adjustment

Adjust

Damaged steering linkage

Replace

and see relative

Suspension

ST 9

topic

under Front

STEERING SYSTEM

SPECIAL SERVICE TOOLS Tool number

For

No

Description

use

tool name

ST27I80001

Steering

Unit

This tool is used

to

mOl

in

drive out steering wheel

All

page

or

Figure No Fig ST4

models

wheel

puller

on

Reference

Caution

Do not hammer on

steering column shaft

v o

J

2

ST29020001 Pitman

SE 116

This tool is used to remove sector

arm

steering pitman

arm

from steering

shaft

620

Fig

6 ST

B210 710

puller

610

SE401

3

ST3I 27S000

This tool is used

to

measure

the

worm

bearing preload

All

Page

ST 5

Page

ST 6

models

Preload gauge GG91030000

Torque

D

wrench 2

I

HT62940000

IJ

Socket

adaptor 3

t 114

3

8

YID Go

318

HT62900000

1 2

Socket

adaptor 4

HT72520000

This tool is used

to remove

ball joint

All

Ball joint

models

remover

SE399

ST 10

SECTION FE

ENGINE CONTROL


l NISSAN I NISSAN MOTOR CO TOKYO

LTD JAPAN

FUEL

EXHAUST SYSTEMS

ENGINE CONTROL SYSTEM

FE

2

FUEL SYSTEM

FE 4

EXHAUST SYSTEM

FE

6

Control

Engine

Fuel

Exhaust

Systems

ENGINE CONTROL SYSTEM CONTENTS DESCRIPTION

FE 2

INSPECTION

FE 3

REMOVAL

FE 3

ADJUSTMENT

FE 3

AND INSTAllATION

DESCRIPTION The accelerator control system is of flexible cable type

so

that the linkage

ul L

f

operates smoothly and the system is not affected by engine vibration

The choke system is

automatically

controlled

@ i

4

@

@

p I @

CV

j

Arrow

E

78

T

2 to 4

mm

B

3 07 in

mm

0 08 to 0 16 in

MUlti purpose grease

I

2 3

Accelerator pedal Accelerator pedal bracket

II

Screw

12

and return

13

Pedal stopper bolt Kickdown switch striker

spring

4

Accelerator pedal arm Pedal stopper lock nut

5

S pring

6

Lock nut

7

Adjust

8 9 10

FE260

Automatic transmission models only

clamp

14

Kickdown switch

Wire holder

15

Accelerator wire

16

models only Switch stopper Carburetor


nut

Accelerator wire outer

nu t

case

Fig FE l Accelerator control sy

FE 2

t

m

Engine Control REMOVAL AND INSTALLATION

E

78

Fuel

Tightening

Accelerator wire

Systems

3 07 in

mOl

38 0

Exhaust

2 7 to

01

torque

to 0 4S

then automatic choke effect will be released

nut

3

kg

Set throttle valve to

m

closed

2 ft b 3

position and

ficiently

I

Remove air cleaner assembly Disconnect accelerator wire from

2

3

Loosen lock nut and disconnect

accelerator wire outer

from wire

case

holder See Figure FE I 4 Remove spring clamp and discon

S

Release auto choke effect

throttle

I with 2

lever is

until

earn

nect accelerator wire from accelerator

pedal

lighten adjust

engine

Keep fingers

by fast idle

opened warms

choke

since

up

valve

Accelerator pedal play is lime See 4

Unscrew

open

adjust a

nut

Tighten lock Figure FE 2

approxi

half turns

accelerator pedal play is 3 in

Pull throttle lever up by hand

at this

zero

FE 2

two and

mately fully

Figure

nut

move

nut

so

that

0 012

mOl

securely

See

arm

Remove two

screws

celerator wire outer

securing

ac

body

and

to

case

1

detach accelerator wire 6

wire suf

until throttle lever is about to 2

carburetor

slackened

completely

with

To

install

the order

reverse

I

of

removal Apply recommended multi purpose

grease

slightly

to

portion

MG shown in Figure FE I Accelerator pedal assembly Remove

I

pedal

ann

Remove

celerator

two screws bracket to

pedal

3

Remove

dash

panel

4

1

accelerator wire from tip of

connect

2

then dis

spring clamp

accelerator

securing body

pedal

ac

from

See Figure FE I

To install

reverse

nut

1

Adjust

2

Lock nut

3

Accelerator wire

4

Dust

@

co

CD

r

order of

the

FE184

removal Fig FE72 AdjU6ting accelerator wire play

INSPECTION I Check

spring

Replace 2

accelerator

for rust

pedal

fatigue

return

damage

or

if necessary

Check accelerator wire

fastening

locations for rust

cases

and

damage

or

5

After completing the adjustment

previously

as

I

Repair or replace if necessary

Make

recommended

multi

explained

purpose grease slightly portion as shown in Figure FE I Also refer to

that

accelerator

the

following

looseness

Apply

4

check the

sure

on the

periodic maintenance schedule

system functions smoothly and quietly without disturbing any adjacent parts

ADJUSTMENT

Depress accelerator pedal down

2 until

Accelerstor pedal and wire

Adjust

pedal

Section A ed height FE I

so

E

Secure

stopper lock FE I

as as

stopper to

obtain

shown in

pedal stopper nut

Refer

bolt

specifi Figure

bolt with to

Figure

sure

throttle valve fully opens Make that the clearance T between

accelerator pedal floor is 2 to 4

reverse

without floor mat

Adjust pedal stop

per bolt and lock nut if beyond limits 3 Check throttle lever if it returns to

the

original position as pedal is released

accelerator

FE 3

soon

as

Automatic

transmission models only

side and dash

0 08 to 0 16 in

mm

Kickdown switch

Kickdown switch adjustment is rect

if it

is

actuated

switch striker when accelerator is

cor

by kickdown

pedal

fully depressed Always tighten switch stopper nut securely after proper adjustment is obtained

Engine

Control

Fuel

Exhaust

Systems

FUEL SYSTEM CONTENTS DESCRIPTION

FE 4

INSPECTION

FE 6

REMOVAL

FE 5

INSTALLATION

FE 6

DESCRIPTION The fuel tank is4Sliters

gal

9 Ji Imper gal

in

tank unit is mounted to of the

rear

II Ji

s U

capacity The the right side

floor

1

Fuel

2 3

Drain plug Filler tube

4

RescfYOir tank

5

Filler hose

6

Breather hose

7

Ventilation hose

8

Evaporation hose

9

Fuel outlet hose and tube

The filler shutter is installed to the filler tube

on

on

California models

For the electric fuel pump

refer to

Section EF

The electric fuel pump is adopted air conditioner equipped models

tank

10

Fuel

11

Protector

12

Bracket

13

Retainer

14

Return

tank gauge unit

tube

FE194

Fig FE 3 Fuel tank

4 FE

Engine

Control

Fuel

Exhaust

Systems

4 A

Detail

Detail

e

Bn

Detail

Detail

G

@ Detail Detail

E

D

Detail

U

B

Detail

Detail T

F

FE261

Fig

Note

REMOVAL Fuel tank

Plug

hose and tube

prevent entry of dust removing

See Figure FE a

prevent entry of dust removing

opening to l

or

dirt while 3

I

Disconnect

2

Remove

the

remaining

battery ground cable

drain fuel

into

a

2

battery ground

Disconnect wires from fuel tank

Fuel filter

hose 4

refer to fuel tank removal

filter

4

FE 5

5

Disconnect filler tube

Remove fuel tank

frofiller

securing bolts

Disconnect two ventilation hoses

fuel tank

Unit gauge is

a

For details

bayonet type and

I

Disconnect fuel hoses from fuel

by removing clamps See Figure

be removed by turning it counter

fuel return hose and fuel outlet hose

can

from fuel tank

clockwise with screwdriver

6

Unfasten clips that hold tube on body and remove tube from the

cable

gauge unit 3 Remove

3

dirt while

vehicle Disconnect

suitable

container

or

under

Fuel tank gauge unit

and receive

plug

4 Fuel piping FE

Disconnect fuel tank gauge unit

wires at connector

Fuel piping

Remove fuel tank

7 Note

Plug

hose and tube

prevent entry of dust

or

opening to l dirt while

removing

tube not

ReservoIr tank 1

2

Disconnect

3

battery ground

cable

Disconnect two ventilation hoses

evaporation

hose and breather hose

Remove reservoir

bolts and

Fuel

sembly

remove

can

tubes so

See Figure are

that

serviced

as

replacement

4 FE an

as

of fuel

be easily done However do

disconnect any fuel line unless

absolu tely necessary I Drain fuel from fuel tank 2

Loosen fuel hose clamps and dis

connect fuel tubes

on

each end

FE18S

tank securing

tank with protector

Note

Plug

hose and tube FE 5

openings to

Fig FE S Removing fuel filter clamps

Control

Engine 2

Fuel

Exhaust

Fuel filter is of

Remove fuel filter

a

cartridge type

and cannot be cleaned Always with

INSPECTION fuel

Check

tank

for

cracks

or

deformation If necessary replace 2

replace

Check gauge unit for rust deforma tion or deterioration If necessary

fIller hose after fuel tank

has been mounted in place Failure to

unit

align the projection of tank

tighten

securely

it

Inspect all hoses for cracks fatigue sweating or deterioration Replace any

gauge unit with O

hose that is

connections

damaged

Replace ed rusted

6

INSTALLATION

Fuel tube

3

any fuel tube that is crack

collapsed

or

deformed

To

Note

Inspect

cording nance

4

to

hoses the

and

tubes

periodic

install

ac

mainte

schedule

Install hose

not

tighten

damaging

of

to

excessively

the surface of fuel tube

the periodic maintenance schedule

or

3

restricted

are

place at

plug kg

m

Fuel tank securing bolt 8 to 1 0 Ikg m 6 to 8 ft Ib

to

Reservoir tank

securing

bolt

Do not kink or twist

tube when they

in

36 to 43 ft Ib

hoses

to

ring

5 0 to 6 0

avoid

damage

Be sure to install

engine and check for leaks

Drain Do

Fasten

according

or

gauge

Tightening torque

clips holding fuel tube on under body securely Failure to follow 2

filter

clogged

order

clamps securely

this caution could result in

Fuel filter Replace fuel

when it is

the

reverse

Run

removal Observe the following I

result in

leakage from around hose connections When installing fuel tank gauge 5 unit with the notch in fuel tank and

replace

Fuel hose

Install

4

follow this caution could

new one

a

Fuel tank gauge unit

5 Fuel tanle

Systems

hose and

032 to 0 44 kg

routed

m

2 to 3 ft Ib

EXHAUST SYSTEM CONTENTS DESCRIPTION

FE 6

INSPECTION

FE 8

REMOVAL

FE 8

INSTAllATION

FE 8

DESCRIPTION The the

exhaust

non

systems installed

on

differ

in

from those installed

on

California

specifications

California Non

models

the California models

The

models

California models

exhaust system consists of

front exhaust tube

a

main

a

muffler

assembly with rear tube mounting hangers brackets and a heat insulator

The exhaust system cOllsists of front exhaust tube ter

assembly

muffler

a

catalytic

center tube

a

assembly

with

a

conver

main

a

rear

tube

mounting hangers brackets and heat insulators The nected

catalytic to

the

is

converter

front

tube

and

center tube with bolts and nuts

FE 6

COD

the

Engine Control Califomia Non

Exhaust S ys tems

Fuel

model

Qf

l tr

Qf Si @

Si

tIJ

Qf

i l

l

t

I

j l tr

Qf

r

l i

Si

l

1 l tr

I

9r 8

1Bi

1

Front tube

2

Exhaust

3

Rear

4

Muffler

5

Rear tube mounting Front tube mounting

6

tube clamp

tube assembly

assembly

California model

6

@@ Qf @

8

fit

0 J

I

1

Front tube

2

Catalytic Center

converter

tube

Muffler

assembly

Diffuser I

Rear

7

tube mounting tube mounting

Front

FE390

Fig FE 6

FE 7

r E

t

ha system

Fuel

Engine Control

Exhaust

Systems

REMOVAL

Install the exhaust system assembly

models

California Non I

INSTALLATION ijl

exhaust

Remove

tube

in reverse order

U bolt

the

clamp 2

of removal Observe

following

Break sealant off at front tube to Notes

main muffler

3 and

connectio n Remove rear tube mounting bolt remove muffler assembly with rear

When there is

b

Remove nuts securing front tube

shaft turn tube

4

tube

to exhaust manifold and remove front

tube

mounting

bolts

Then detach

FE189 c

the

exhaust

Q

d

off at t lse ant 1e connection by lightly tapping around the tube witlJ a hammer and twisting 8 FE

tap on the front end of muffler while pushing it toward rear The mumer assembly can

After

old

muffler See Figures FE 7 and 2 Using a rubber hammer

then be taken out

See Figure

I

Remove all heat insulators

2

Remove

tube

exhaust

U bolt

vibrations may be transmitted to the vehicle body or

Break sealant off at center tube

rear

Remove

Exhaust manifold to

tube mounting bolt

and remove muffler assembly with tube 5

Tightening torque

e

to main muffler connection

Remove

front tube nut

rear

19 to

bolts securing

U bolt

14 to 15 ft lb

Remove bolts and nuts

Mounting

securing

710 9 ft lb Front tube mounting bracket bolt california models

Remove nuts securing front tube and remove front

to exhaust manifold

Fig FE 7 Breaking Bealant

bolts

mounting

bracket bolt

1 0 to 1 2kg m

catalytic converter to front tube and detach catalytic converter

tube

securing nut kg m

19 to 2 1

Then detach center tube

FE187

m

lb ft

catalytic

center tube mounting bolts

7

5 kg 2

14 to 18

converter to center tube and remove

6

that

If any of the above parts is not installed properly excessive noises

clamp 3

check

installation

mounting brackets and mounting rubbers are free from undue stress

California models

4

FE 9

connecting

running

following point Break

the manifold

in

propeUer

or

center line of

haust gas leaks and entire system for unusual noises with engine

rubber hammer

tube connections pay attention to the I

along

and obtain proper clearance Check all tube connections for ex

Fig FE 9 Tapping muffler with

disconnecting

clearance between

unit

front tube When

110

front tube and floor

Remove front tube heat insulator

5

tube until it touches

emboss

tube 4

front

Insert

a

19 to 2 1

Then detach

kg

m

14 to 15 ft lb

front tube

Catalytic

converter to front

and center tube bolt California models 3 2 to

3 4

kg

m

23 to 31 ft Ib

INSPECTION I

Check

cracks Qr

muffler

and

tubes

connection

damage

Replace

any

part that

is

damaged

beyond limits 2 FEl88

Fig

8 FE

Twisting muffler

Replace

insulator that

If exhaust tubes

for

etc

use

are

separated

t renew muffler

at

assembly

the Genuine Nissan Sealant

Exhaust Sealant Kit 20720 N2225 bracket and are

cracked

sweated

FE 8

mounting

fatigued

or

or

equivalent

See

Figure

FE IO

eliminate gas leakage at the sure to observe the following

joint

to

Be

Fuel

Engine Control

Exhaust

Systems Start

7 for

ten

and let it idle

engine

minutes

to

minimum

slowly hilfden

sealant with the heat of exhaust gas Sealant tube

8

polyethylene

condition of sealant

Check the

before driving the vehicle It is also essential that the vehicle should not be

Injector

accelerated minutes

sharply for 20 to 30 subsequent to this operation

Noles a

The sealant should be used within

Exposure of sealant cause

Wipe clean all tions of tube joints thoroughly 2

on

3

as

Be sure to

place

cap back to sealant

tube since sealant will

dry

an

place

a

Do not

ture

assembled unit

tube until it touches

to the skin may

keep

the sealant tube in a

where the ambient tempera is

above

I040F

Insert front

the kit

rash Wash sealant off the

sealant

the vehicle

on

skin with water c

place in

mount

Temporarily

muffler assembly

the contact por allow them to dry

indicated

case

b

I

term

guaranty

Fig FE IO Exhaust sealant kit

400C

A I040F 4QoC

above

hardened

cannot be used

The most

suitable storage temperature is from 15 to 350C 59 to 950F If sealant

emboss

becomes hardened because of low

temperatures 5

b nlfrnnjj Ij lJ

Fig FE

4

ll

Torque

female

securing the male and the

connection

Tightening torque is 1 6 to 12 to 14 ft lb 5 Squeeze approximately cu

in

2 0

Position nozzle of injector to the guide and press it there firmly Inject

kg

m

sealant slowly until sealant begins to flow out of the slit of tube This indicates

that the bead requires

further sealant Excessive sealant cause

a

clogged

tube

See

no

can

Figure

FE 13 5 CC

31 0

of sealant into injection from

sealant tube See Figure FE 12

sealant is softened tube

at a

1040F

After

injecting

thoroughly

the

sealant

wash

in clean water to

injector remove

all traces of sealant

FE191

Fig FE 13 Injecting sealant FE 9

Do not warm

temperature a long time

over

400C

for

d Thoroughly FE263

at

in

6

Exhawt tube connection

nut

Cll

Fig FE 12 Squeezing sealant to injec tor

J @L

tubes

0 31

FE1l1

mm

m

cc

wann

tube with lukewarm water until the

Approximately

read

the

instruction

sheet furnished with the kit before

using the

sealant

i

SECTION BF

BO DY

FRAME


CAB BODY AND FRAME

BF

2

REAR BODY

BF

5

BODY FRONT END

BF

7

HOOD

BF

8

DOOR

BF 11

WINDSHIELD GLASS

BF 16

INSTRUMENT PANEL

BF 17

INTERIOR TRIM AND

CENTER CONSOLE SEAT


LTD JAPAN

BF 18 BF 19

Body

Frame

CAB BODY AND FRAME On the 620 series models

chassis classified into three types the standard wheelbase model long frames

The frame consists of right and left side

are

members which

are

heavy

linked to

is

gether with crossmembers to form a rigid structure that can withstand

wheelbase model and Deluxe Cab

loads The second crossmember

located somewhat to

the

rear

permit individual replacement of transmissiol

to the

FRAME ALIGNMENT STANDARD WHEELBASE MODEL

9

rd

9

8

0

ij

1sol

r

00

1

l

085 42 721

1

4 069

r1

f

7

42

1 587 5 X 62 50

9ClSCl

b b I 1

I

J q

e e 6

1

I

1

JA

t

1 11 i11

1

r

1

H

10

1 I

I

OO

175 6 89

5 37 11 942

I

r

T

1007

284 18 11

L

39 65

295 11 61

r

r c

8 d

8

o

M

o

BF025B

Fig BF I Underbody dime1l8ion

SF 2

Standard whee

b

e

Frame

Body LONG WHEELBASE MODEL

l1 4

In

IS

S M

t

r y

J

t

v

D

c

I

b

f

G

c M 0

raj

V N

085 42 72

78

1

350

I I

1

d3 1

20 63

U n

So

p

Ii

I

T

II

L

r

J

t

I

I o

10

9 1

M

y r

M 0

I

bi

1

I

0 1

873 8

mrn

IN

0

v

p v

1

Ir

M

e

C

o

M

BF0268

o

Fig BF 2 Underbody dimensions Long wheelbase

DELUXE

CAB

17 C

l

0

y r

dJ

M

r

2

iO

1

b

I

00 o

V

JSO

0

0

I li4

t

I

37 11

l

1

284 18 11

bu

I

007

39 65

b n

It o

U

j

1

1161

c

I

Jr

0 N

00

8Qa 3 OS

t

A

942 5

r

M

0

1

1 b

I

t

c

tl

f 0

1 085 42 72

1

P

N

S

1 069 4 42 10

b

u

r

I

T

M

8 o It

R M

o BF027B

Fig BR 3 Underbody dimensiom BF 3

Cab Delu

Frame

Body CAB BODY

2nd mounting

Ist

mounting

1

Bolt

2

3

Plain washer Rubber washer

4

Upper

5

Bottom rubber Plain w er

6 7

Upper

8

Lower washer

BF472A

1st mounting

2nd mounting

rubber

washer

Unit

mm

in

3rd mounting

Fig BF 4 Cab body mountings

REMOVAL AND

II

INSTALLATION

from frame and pull it out into engine

at

compartment

nect cable from dash

Remove

12 Remove

from

battery

engine

2

Disconnect oil cooler hoses from automatic

radiator model

transmission

only

housing

gear

Loosen hand brake control cable brake control lever

Note

Disconnect

carbon

vacuum

rolling

between

gallery

and canister to intake manifold

canister

to

wheels to prevent vehicle from

rear

hoses

24

off accidentally

Free

Disconnect air conditioner tubes from condenser if so equipped

pump air cleaner hose at air cleaner

25

4

15

engine side

Drain water from and

completely

cooling

remove

system radiator and

condenser if so equipped 5

Remove engine hood from hood hinges after scribing hood for rein stallation 6 and

remove

bumper stay

from frame

front bumper

7

Remove radiator grille

8

With

the aid of Steering Wheel

Puller ST27 180001

remove

wheel from steering shaft 9 Remove steering gear sector

shaft

steering

arm

from

using suitable

puller 10

air

to

pump

air

Disconnect air conditioner hoses

from compressor if so equipped 16 Disconnect air cleaner duct from

body 17

Disconnect

Master Vac

vacuum

Remove

18

Remove

snap ring and

control

transmission

striking

lever

pin from

guide

and remove control lever

19

Disconnect

fuel

securing steering and insulator in posi

screws

Disconnect

26

and

22 tubes

Remove

all

brake tubes and clutch tube at

4 BF

on right engine mounting

frame

29

With the an

use

of suitable ropes

overhead hoist lift cab up

slowly

and

body

place

it on a

up cab body

use care

clutch

cylinder clips securing fuel

cab body

rear

level surface

at connectors

brake

near

Remove six bolts securing body

28

straight

Disconnect

at

member

20

21

hoses

harnesses at their connection

strainer

evaporation hose

heater

Disconnect wire harnesses from

and

Disconnect fuel return hose and

car

related engine electrical parts 27 Disconnect engine and chassis

to

hoses at fuel

accelerator wire from

buretor

sidemember

tubes from each master

shaft dust seat tion

Disconnect

hose at intake manifold

Remove

steering

14

Then discon

panel

Place blocks against front and

canister

at canister

3

23

Disconnect speedometer cable at

transmission 1 3

compartment

steering

Note

In

lifting

not to dash it

body mately

against engine or rear Cab body weighs approxi 220

kg

485 Ib

Body 30

For

steps

However

installation

reverse

Frame

above

observe the following

instructions

i

Ifthe cab

body is

to be

replaced

note

position and location of insula

tors

and

washers

used

See

Figure

2

Adjust

hand

brake stroke pro

perly 3

Air

system

bleed

brake

and

i

o

4 BF

clutch

thorougWy

kg

q

j 1Q

Cab body to frame mounting bolt torque 1 6 to 2 2

k

b

rr1

m

12 to 16 ft Ib

crru

V

J

4

n

8F630

Fig BF 5 Lifting

up

cab body

REAR BODY

1

Bolster

2

Shim B

3

Bolster

4

Shim A

5

6

Frame Rubber washer

7

Plain washer

BF664

Fig BF 6 Rear body mountings

REAR BODY REMOVAL AND

tank

INSTALLATION

body

The

rear

Remove fuel

tank

from

rear

5

Remove eight

rear

body attaching

bolts

body is securely fastened eight places It should

to the frame at

be hoisted after the fuel tank is moved from the rear body Use the


guide when removal

or

as

a

installation of

rear

body is

I

Apply parking brake

2

Disconnect cables from

3

Disconnect

necessary

rear

lamp wiring harness at 4

re

battery

combination

connectors

BF665

Disconnect fuel hoses from fuel

Fig BF 7 Rear body mountings BF 5

Frame

Body 6

Attach

rear

body

and

lift

ropes to hooks in 8 BF shown in Figure

lifting as

body slowly and

rear

up

REAR GATE

00

REMOVAL AND INSTAllATION W

1

carefully

Notes When

a

lifting

body make

rear

that it is in

a

good

sure

balanced cond

ition b While lifting rear

any

The

c

body

use care

to hit

cab

against

body

or

adjacent parts rear

Rear gate chain

1

not to allow

body weighs approxillllte

@

Iy 130 kg 286 Ib

2

Rear gate chain bolt

3

Rear

4

Shim

S

Hook handle

6

Reargate

body

BF661

Fig BF 9 Rear gate I

Open

2

Remove

rear

2

gate

body

rear

at any

I

adjust

To

order

rear

of removal

body

reverse

Carefully

the

or remove

observe

thickness rom

adjust rear gate hook loosen attaching bolts and move rear gate hook or left right in elon down up holes as gated required

reverse

the

1 6

height

shims at

mm

FRAME

Optional REMOVAL AND INSTAUATION The

points the

To

GUARD

Two sizes of shim To install

required

gate should be

portion add 7

in the left and

two

adjusted so that there exists an equal clearance between body and the periphery of rear gate There should be no stepped The

rear

gate

3

ALIGNMENT

up

rear

Remove rear gate hinge attaching 3 bolts and take out rear gate and rear

ear

order of removal

Fig BF 8 Lifting

adjust

gate

gate chain from

gate hinge shims 4 To install rear gate

BF0288

To

right directions loosen rear gate hinge attaching bolts and move rear gate as

rear

of rear gate

rear

are

gate hinge

available

in

0 0630 in and 0 8

0 0315 in

guard frame optional equipment I

guard frame at guard frame optional guard frame

bolts and detach

To install

reverse

as an

nine

Remove

taching 2

is furnished

the order of removal

the following instructions Make

sure

that spacers and shims

used with bolts

are

properly placed

rr

r

original positions Refer to Figure BF 6 for the location of these parts The rear body to frame attaching

in their

bolts should be

kg

m

torqued

24 to 30 ft Ib

to

3 to 4 2

f r @ L

C

s

i SF673

Fig BF lO Guard frame 6 BF

Frame

Body

BODY FRONT END

4

ZID @ 1 2

Hood

3

Hood

@

Hood support rod

4

bumper Fender

5

Bumper bracket shim

6

Bumper side bracket

7

Bumper

8 9

Bumper stay

10

7

@

Front apron Radiator

BF029B

grille Fig BF

3

FRONT BUMPER REMOVAL AND

INSTALLATION L

Remove

bumper

to

For

installation

reverse

above

steps observing the following Check to be certain that I

fender at

taching bolts Remove four bumper stay to side frame front attaching bolts Pull bum

six

guide studs enter holes in radiator support lower frame before tightening top screws

2

forward per assembly straight reverse 3 For installation

steps Align bumper with front fender and apron then tighten them up

radiator

and two

on

Radiator grille

2 3

Guide stud

4

Radiator

Guide

632

stud hole support lower

grille by

re

Fig BF 12 Radiator grille guide

six on

top

studs

both ends

Remove

ornament

grille by removing radiator

1

frame

screws

grille

on

Remove radiator

3

Disconnect front turn

radiator

nuts from behind

2

at

bumper grille signal

wire

connector

Remove front apron by removing

For

steps

REMOVAL AND INSTAUATION Remove

Remove front

S

RADIATOR GRILLE

I

I 2

attaching bolts

@

B

moving attaching


4

above

Body front end

FRONT APRON

harness

CD

11

Align grille

with head lamps and

fenders

BF 7

installation

reverse

above

Frame

Body

However

COWL TOP GRILLE

observe the following items

When installing air box drain apply adhesive to its lower end

I

@

@

2

Align cowl top grille with fend

ers

FRONT FENDER

1

Cowl top grille

2

Cap

3

Air box dtain seal

4 5

Cowl top Air box drain

6

Screw

6F633

Fig BF 13 Cowl top grille

REMOVAL AND

2

Open engine

windshield

blad Remove cowl top

3

screws

hood

two

Remove

I

Remove front

2

Remove radiator

3

Remove front apron

4

Remove cowl top

S

Remove hood bumpers

bumper grille grille two

on

each side

INSTALLATION I


wiper

grille

straight forward to

To

Remove

nine

attaching

screws

BF ll

Remove air box drain

5

6

front fender to hood ledge See Figure

remove

4

grille attaching

Pull

install

reverse

above

steps

7

To install reverse above

steps

HOOD HOOD 5

REMOVAL AND INSTALLATION 1

Place protective

fender and cowl top 2

covers over

front

grille Mark hinge

1

Female lever

hood and loosen offfour

2

Safety

bolts securing hood to hood hinge Use

3

Return

4

Dovetail

S

Lock nut

6

Hood lock pring

7

Spring

Open engine

locations

extra

on

caution

hood

to

avoid

damaging

painted surfaces of fender and cowl top grille 3 4

Remove engine hood To install reverse above

J

Four slotted holes in hood hinge provide for fore aft and side adjust to correct space between hood and hood and cowl top

and fender

grille just enough

to

engine hood and move hood to desired position if necessary to correct

move

space To make vertical

hinge bolts just permit movement of

Loosen hood to

far

enough

to

hood Shift hood in elongated hole until hood parallel space is reached between cowl top grille Tighten and fender or 2

j I

bolts securely

adjustment adjust

height of dove tail bolt

bolt

Fig BF 14 Hood lock male and female

ADJUSTMENT

Loosen four bolts

spring

BF641A

pro

cedures

ment

catch lever

8F635

at hood lock

Fig BF 15 Engine hood alignment

male until hood is flush with fender BF 8

Frame

Body Vertical

Note

adjustment

5

should be

and female

adjustment

has

D

been

completed 3

bolts and

move

attaching

r

hood lock male and

female in the lateral and fore and aft directions as

required

lock

nut

dove tail bolt

driver to secure

1r

To correct hood lock alignment

loosen two hood lock male

Tighten

holding

carried out after hood lock male

firmly while with

a

screw

adjustment

Tightening torque Lock nut of dove tail 1 9 to 2 6

kg

m

14 to 19 ft lb

BF642A

Fig BF 16 Adjusting hood lock male

provides for vertical adjustment in aligning hood to make it flush with

Male and female attaching bolts 0 45 to 0 60 3 to

Dove tail bolt at hood lock male

4

Tightening torque kg

m

fender To correct loosen lock nut

3 ft Ib 4

on

dove tail bolt and turn dove tail bolt in or

out as necessary to obtain

a

correct

height

BF643A

1

Lock nut

2

Hood lock

male

3

Safety

catch

Fig BF 17 Doue tail bolt height adjustment

HOOD LOCK CONTROL

JI

I I

i

r

J

lPP J jJ

I

f

r

j f

ifryI ff

U

J aj

Sr I

1

Dove tail bolt seat

I

2

J

3

Lock nut Cushion rubber

ii1iiilliiijiWI Y

4

7

j 1

5

Spring Spring

6

Dove tail

7

8

Clamp Clamp

9

Hood lock female

10

retainer

bolt

Control cable assembly

JJ BF644A

Fig BF 18 Hood lock and control cable

8F 9

Body

Frame

REMOVAL AND

I

INSTALLATION

spring for rusting

Remove hood lock male by

I

re

2

moving two attaching bolts 2

To

remove

remove

grille

Back off two

lock

to

dash

side

paneL Disconnect female and

cable

remove

at

hood

BF645A 1

Hood tock handle

3

Clamp

2

Hood lock handle

4

Hole

bracket

5

Attaching bolt

lock

cable clamps Pull

Fig BF 19 1MtalIing hood lock handle

cable out into cab 4

brocket

removal

reverse

or

lever and return

disengagement

be

sure

engine

that

hood

hood latch has been

safety

catch

properly when

disengaged

0l

they

are

5

To

procedure

check to insure that

Mter installation

properly aligned install hood lock handle

sembly following notes Check to I clamps are tight

reverse

steps

I

ADJUSTMENT AND

as

observing the

I

If hood lock handle is heavy turn

nun

0 3t5 in

coun

Fig BF 20 Safety catch lever to radiator upper support

terclockwise to reduce tension of hood

acVu5tment

dove tail bolt of hood lock male lock

secure

spring

Lock nut of dove tail bolt should

Install hood lock handle bracket two of four holes

BF409A

11 mm 433 0 in

INSPECTION

be certain that cable and

place by using See Figure BF 19 in

and

To install hood lock male and

female

2

Make

hooks

attaching hood

assembly

cause

may

3

@

handle

fatigue

tween female lever and dove tail bolt

be taken out Remove two bolts

Check female

lever

securing hood lock female in position Hood lock female can now

bolts

3

catch lever

safety

deformation

spring for deformation fatigue or rust ing Improper operation of female

hood lock female first

radiator

Check

fust be loosened

When

If looseness is noticed hood is not

tight and will vibrate To

correct this

turn bolt clockwise and recheck

2

Lubrication

Check hood lock mechanism

follows

thoroughly as

or

adjusting

the

Also lubricate the lever of

the hood lock female for smooth and correct

BF 10

checking

hood lock lubricate the pivot catcher and return spring of secondary latch

operation

Body

Frame

DOOR CONTENTS DESCRIPTION

BF12

DOOR

BF 12

REMOVAL


BF 12

ADJUSTMENT

ALIGNMENT

BF12

DOOR

RUN

VENTILATOR

WINDOW

Optional


GLASS AND REGULATOR

BF14

AND INSTALLATION

BF14 BF14

LOCK

REMOVAL

BF12

REMOVAL AND INSTALLATION DOOR

DOOR

BF12

TRIM AND SEAL

REMOVAL AND INSTALLATION GLASS

DOOR

BF 14 AND INSTALLATION

BF15

ADJUSTMENT LOCK

BF 15

BF13

DOOR

STRIKER

BF 13

WEATHERSTRIP

BF 15 BF 15

BF13

DESCRIPTION

8F 15

BF13

REMOVAL

BF 15

AND INSTALLATION

CD CV CID

@ @ @ 1

Door

2

Window outside

3

Wmdow inside weatherstrip

4

Door

5

Rear

6

Door

weatherstrip

weatherstrip glass run rubber

7

finish holder Rear lower sash

8

Seal

9

Door

screen

12

weatherstrip clip glass run rubber Lower door hinge Upper door hinge

13

Front

14 15

Door glass Glazing rubber

16

Door

10 11

j

sash

Front

lower sash

glass bottom channel

BF030B

Fig BF 21 Door without ventilator window

BF 11

Body

Frame

@ I

CD 1 @

r L

1

3

Door sash Window outside weatherstrip Window inside weatherstrip

4

Door

5

Rear

6

Door finish holder

7 8

Rear lower sash Seal screen

9

Door

2

@ ID @

c

@

AJ

@

weatherstrip clip

11

Front glass run rubber Lower door hinge

12

Upper door hinge

13

Front lower sash

14

15

Door glass Glazing rubber

16

Door

11

18

Lower support Upper support

19

Door ventilator assembly

10

@

atherstrip glass run rubber

glass

bottom channel

BF031B

@ ntilator window

Fig BF 22 Door with 4

DESCRIPTION The outer

rigid

door

consists

The

curved

ALIGNMENT

a

Elongated holes hinge and door

window

is

also

a

ventila

available

as

to

an

BF023

option The

weatherstrip

is inserted

on

the door side

2 3

Separate

lower door

While supporting door

back off


inside cab

With door in full open position a garage jack or stand beneath

hinge

hole

from dash side trim

body hinge attaching

I

To

as

above

upper and lower bolts accessible from to

three each

Door

place

door to support its weight when bolts removed Place rag between door and jack or stand to avoid damaging

I

lf p1JJ

W

1

painted surface

door

move

lion to obtain a

door

to

door

alignment

loosen

door to desired posi parallel space between

sides and door

opening

Also

check to be certain that contacts vent

weatherstrip body opening evenly to pre

entry ofmud and water

DOOR TRIM AND SEAL INSTALLATION 1

door

Remove

screw

securing

handle escutcheon

inside

remove

es

cutcheon

i

2

Remove

handle and

Sl

fit

REMOVAL AND

t

I

door

can now

be taken out from cab body

are

proper

adjust

bolts and

cover

DOOR

assure

opening

Fig BF 23 Supporting door

into

the groove on the door sash side and is

attached by clips

in

lock striker pro vide for up and down forward and backward and or sideways adjustment

glass provides greater incorporates

three each

door

room

A door that tor

and

to form

structure

shoulder

removal pro

reverse

cedure

of inner

panels welded together

To install

Optional

handle and

j

screws

arm arm

which hold pull

rest in

position Pull

rest can then be taken

out 3

Fig BF 24 Removing door hinge bolt

8F 12

Pull

retaining spring

off regulator

handle Take out regulator handle and seat washer

Frame

Body

5

Remove door

6

Remove glass

front and

glass run

rubbers from

lower sashes and from

rear

those of fixed door caution

Use

avoid

to

damaging

rubbers during removal operation Remove front 7 and rear lower door

sashes

is not

provided

8

1

BF640

On vehicles

lator Seat

window

washer

BF 25 Removing regulator handle

To install

ing

4

door finish are not

With

taining clips

exercising

pry

off

re

care

not

to

Adhesive

f

Section A

I

A

i

jl

II

Ii

iif

A

ir

coil

J

IIIII

Fig BF 27 Adhesive for seal

With door glass up set regulator handle at an angle shown in Figure

To

cedure

install

J

l

replaced into

be

position

Sure

to

screen

securely

water sealed door

This

Broken be

leaking

new one

to

can

evenly applying adhesive inside door

Fig BF 28 Installation angle of regulator handle

back

ensure

be done

a

by

to grooves in

panel must

suspected

be replaced with

to a

1

Door sash

2

Glass

3

Adhesive

run

rubber

Fig BF 29 Applying adhesive to glass run ru bber

Optional

REMOVAL AND INSTALLATION I

Remove

GLASS RUN

of door

REMOVAL AND

to and

INSTALLATION I

With

door

in

full out position

five ventilator window

2

Remove

regulator 3 seal 4

pull

handle

2

For detailed

relative

topic

Lift frame out

procedure

under

refer

Door Glass

Regulator Remove nuts and spring securing end of ventilator window to

lower

lower glass all the way

screen Or one

CID BF641

frame attaching bolts

is to be

cement it

good fit

WINDOW BF462

notes

When water seal

i

a

DOOR VENTILATOR

reverse

However

ing instalJation

run

CD

Spring

1

removal pro observe the follow

glass

to

and fit it correctly Particularly care should be taken at corners and contact

BF 28

inside door

6

adhesive

door sash contacting face

screen

2

from

on

I

900 screen

clean

J

Fig BF 26 Removing door finish

Separate water seal panel

adhesive

lUJJ

d 5

applying

nil

BF641

ldI

I

Apply

rubber

face to assure

JJ

A

I a L

Before

2

f

damage clips

I

removal pro observe the follow

reverse

However

the inside ofdoor sash

damaged

screwdriver

a

ventilator lower door

rear

notes

I

When removing door finish it is important that inside door panel and

with venti

remove

sash 9

cedure

Fig

equipped

window frame and

Regulator handle Retaining spring

3

when ventilator window

arm

rest and

frame Work off rivets which hold upper end of ventilator window to frame 3

handle

Remove door

fmish and water

take out window

screen

Remove outer and inner weather

4

To

cedure

strips from door BF 13

install

reverse

removal pro

Frame

Body DOOR GLASS AND

REGULATOR CD j

fffi

I

BF035

Fig BF 32 Removing door

12

To install

reverse

glass

removal pro

cedure

ADJUSTMENT Fig

BF 30 Door

gl and regulator

In and out

I

justment REMOVAL AND

10

INSTALLATION

lator remove three bolts

L

Open

lower glass

door

way 2 Remove iflllide

all the

door handle

es

cutcheon 3

Remove

pull

handle

Remove

arm

rest

5

Remove regulator handle

6

Remove door finish

7

Peel off water seal

suitable

plain

place

a

driver and door

lifting

it

up

Back off the five

guide

channel

base

remove

or

large

access

front

or rear

fore and aft ad

be

required The

ease

with which window

bly raises and lowers depends

attaching screws regulator Take out regulator assembly through

screwdriver

piece of rag between

go

Remove ventilator frame attaching bolts and lift frame straight up out of

to

screen

similar flat bladed tool io

glass

the bottom of door

11

erstrips from door being sure not to scratch door paint during operation a

to

with venti

securing door

bottom channel then let

straight

Work off outer and inner weath

Use

glass

equipped

door Remove door glass by

4

8

On door

and

made by moving sash and guide channel as

can

hole in inside door

panel

justment of lower

sash

rear

should

front lower sash 2 Fore and aft

lower be

assem on

ad

sash

Rear

parallel

with

adjustment

is deter

mined by position of guide channel and front lower sash Moving front lower sash backward reduces window

play

in

assembly

DOOR LOCK

and

screw

panel

j CID @ 1

Outet weatherstrip

2

Screwdriver

3

Piece of rag

BF643

Fig BF 31

9

outer

1

Escutcheon

8

Nylon nut

weather trip

2

Inside handle

9

3

Spring

Removing

Remove three door glass bottom

channel

attaching bolts glass by lifting it straight

Remove door up

4

Door lock knob

11

Locking plate ring LOcking plate Door lock cylinder

5

12

Door lock

6

Knob grommet Outside handle

13

Stopper

7

Outside handle rod

10

BF 14

BF410A

Fig BF 33 Door lock mechonillm

Frame

Body REMOVAL AND INSTALLATION

ADJUSTMENT OutsIde door

I

Open door

2

Remove

inside

door

handle

es

cutcheon

Adjustment handle

is

of

play

pull

handle

ment of

4

Remove

arm

rest

outside door handle rod

regulator

Remove

6

Remove door finish

7

Peel off water seal Raise door

8

glass

screen

below

nut and

to full up

play

as

is 10

mm

up and down

0 039 in

between door

locking plate

lock latch

WEATHERSTRIP

Inside door handle Remove

rear

lower sash attach

iog bolts Disconnect remote control rod

11

from key cylinder and outside door handle 12

Remove three door

lock

DESCRIPTION

Elongated hole in inside door handle provides for play adjustment of

The

inside door handle

clamp

Correct play is 10 or

below

as

provide for

fore and aft adjust

or

to establish proper engagement lock striker and door

ment

measured between nylon

Remove inside door lock knob

10

three

Elongated holes

posi

tion

9

nylon

Correct or

lock striker

should be made after door hinge has been adjusted correctly

controlled by play adjust nut on threaded end of

Remove

handle

Adjustment of door

in outside door

3

5

DOOR LOCK STRIKER

handle

mm

0 039 ill

weatherstrip

is

by clips

retained 19

to the door sash and

by panel No adhesive is used the weatherstrip to door

to the door to retain

measured at control rod

assem A

bly attaching 13

screws

L A

Remove two inside door handle

attaching 14

screws

take

inside

with

Together

handle

door

out

assembly through large

door

lock access

as

an

hole in

door panel 15

Remove

handle handle 16

two

attaching can

nuts

17

door

Outside

door

Section A

A

Section B

B

j

then be taken out

Remove lock

cylinder

outside

and detach

plate from key key cylinder

I

To install door lock assembly 1

outside and inside door handles and

key cylinder

reverse

removal

pro

cedure

rB 18

Lubricate door lock with grease which meets the requirements of MIL G I0924B

or

equivalent

as

I

B

BF645

listed Fig BF 34 Door weatheratrip

below ALVANIA GREASE RA BEACON 325

SHELL

ESSO

MOBILE GREASE 22

MOBIL

REMOVAL AND INSTAUATION I

Open

2

Free

3

door

Pry off clips

remove

weatherstrip

from door sash

4

BF 15

door

panel

weatherstrip

To instaH

cedure

clamp

from

reverse

removal pro

Frame

Body

WINDSHIELD GLASS WINDSHIELD GLASS DESCRIPTION The windshield

glass

is retained in

body glass opening through

the

There

weatherstrip drain holes

one

on

are

twelve

the

water

each side of the

bottom of the glass opening and ten along the length of the weatherstrip

Working from inside vehicle push windshield glass out of body opening by hand starting at right and left toward upper COIners and working out ends 6 After removing weatherstrip from 5

top and sides of body opening lift glass up sufficiently to permit removal of weatherstrip from bottom flange pry weatherstrip out of position This operation requires two men

With aid of

3

being sure weatherstrip lip aligns ith body opening flange 4 Slowly pull cord ends from inside to overlap weatherstrip channel on body opening flange starting at center top and working out toward ends This operation should be done while one man pushes glass against body opening from outside

technique should be

installing

glass opening

and

windshield glass on

left and bottom

ap

wea

th

body

weatherstrips channels

Clean weatherstrip

I

plied right erstrips to

the following checks

press wind

from outside

INSPECTION Prior to

helper

assembly against body opening

shield

The same

make

a

re

those found with cracks

or placing of deterioration signs Clean body openings noting if 2 1

Weatherstrip

BF473A

2 Windshield glass 3 Water drain hole

these are distorted or corroded

INSTALLATION

Fig BF 35 Windshield glass and weatherstrip

L

Fit

sure

tioned

REMOVAL Place

1

protective

strument

sun

3 so

inside

rearview

mouldings

if

Using

a

putty knife or similar pry lips of weather

flat bladed tool out

flanges

Adhesive need not be applied

mirror

visor

equipped

strip

top

covers over en

Remove windshield

4

Fig BF 39 Fitting weatherstrip

panel

Remove

and

weatherstrip on glass making properly seated and posi

is

front fender seat and in

gine hood 2

it

of

place from opening

top and side

0

Fig BF 40 Fitting weatherstrip bottom

Fig BF 37 Fitting weatherstrip on glass

of body

weatherstrip is to be reused it is important that it not be damaged during this operation

BF650 BF641

If

2

Insert

around

a

draw cord

weatherstrip

completely

outer channel

Install

5

moldings

on

weatherstrip if so equipped 6 Install inside rearview mirror and sun

i

windshield

visor

I

dYii

Q

1

BACK WINDOW GLASS AND SIDE WINDOW GLASS

Windshield glass

2

cord Draw

3

Weatherstrip

8F648 BF041

Fig BF 38 In8erting draw cord around Fig BF 36 Removing weatherstrip

weatherstrip BF 16

outer channel

Refer to relative topics under Re and Installa Inspection

moval tion

of windshield

glass

Body

Frame

INSTRUMENT PANEL

wiring harnesses

1

5

Disconnect

at connectors relative

wiring har

from instrument panel at

nesses

con

nectors 6

Remove

column

steering

shell

Removal of steering wheel at this stage facilitates further removal of instru ment 7

panel Remove

knobs

two

side

ventilator

Remove package tray attaching

bolt and detach package tray

2

Bracket welded to dash

panel BF646A

2

Nut

3

Instrument

panel assembly

Fig BF 41 Instrument panel assembly

I

Package tray

2

Side

ventilator knob

Fig BF 42 Package tray

8

INSTRUMENT

PANEL

REMOVAL AND

INSTALLATION

bly 2

Disconnect heater control cables from heater assembly 3

Disconnect

the back Disconnect battery cables

4

speedometer cable of speedometer

on

Disconnect antenna and speaker

8F 17

Support instrument panel assem remove five attaching bolts

and

from it 9

Withdraw

instrument

sembly while lifting 10

To

removal

install

it

panel slightly

reverse

as

the order of

Frame

Body

INTERIOR TRIM AND CENTER CONSOLE HEADLINING DESCRIPTION The

headlining assembly

is

of

a

suspension type which is held in place

by listing

wires

The design is quite

similar to that used in

a

passenger

car

2

Install listing wires in

place

on

roof rail 3

attach front

First

headlining

to

flanged portion of roof rail Secondly attach the rear edges of headlining in place while pulling the headlining material to avoid wrinkles the

4

Attach the right and left edges of

headlining tions

ct

5

material to the

using

Cut

care

excess

cept for that front center

flanged

por

to avoid wrinkles

headlining at

material

ex

the upper areas of

not and rear pillars by body side welt The edges headlining material at these areas

covered of

should be

properly

cut that it can be folded

so

place Install garnish on in

I

6

2

of headlining at

3

7

Drill

a

hole in

4 room

5

A

6

lamp

the extreme end

pillar headlining

rear

is located

Install

where room

lamp

7 8

BF648A

9

Fig BF 43 Headlining

8

Install body side welts

9

Install windshield

glass glass

10

Install back window

11

Install assist rail

sun

visor and

inside rearview mirror

BACK TRIM AND BACK INSIDE FINISHER DELUXE CAB

REMOVAL 1 ror

Remove two inside rearview mir

attaching

screws

and detach

2

CD

Remove three

screws

3

and detach

sun

sun

J I

visor attaching

visor

and detach assist rail

Remove

5

Open doors and remove body side

room

lamp

welts on each side Remove

windshield

glass

1

Headlining cloth

4

2

Clip

5

3

Garnish

Remove back window and weath

erstrip 8 of

Remove

garnish securing headlining to rear pillar

Door glass Back window glass

Fig BF 44 Removing gami8h 9

Detach

headlining the end

Back trim

BF661

I Move floor carpet aside Remove four bolts attaching back

2

trim to floor

and

weatherstrip 7

INSTALLATION

I

CID

II

4

REMOVAL AND

I

Remove two assist rail attaching

screws

6

rhir

rear

view mirror

all

cemented

from

edges of

flanged portion

of

Disengage listing wires from headlining

roof

rail and detach

INSTALLATION I

Apply

adhesive

outer surface of

attaching

Remove five trim

clips

and detach

back trim

roof rail 10

3

cement

flange

surface evenly 8F 18

and

to

the

headlining

4

Installation is the

reverse

order of

removal

Back Inside finisher I

Remove seat belt retractor

2

Remove five trim

clips

and detach

back inside fmisher 3

Installation is the

removal

reverse

order of

Body

Frame Air conditioner equipped models Remove two bolts from front of

I

center console 2

Remove two bolts from the rear

2 and

1

Back trim

2

Back inside imisher

3

Clip

remove

center console

CONSOLE WITH ARMREST

1

DELUXE CAB REMOVAL AND

INSTALLATION BF0328

Fig BF

45

Back trim and back inside finisher

I

Remove two bolts from front of

console armrest unit 2

Remove

box and 3

one

remove

bolt in the console

center console

Installation is the reverse order of

removal

CENTER CONSOLE REMOVAL AND INSTALLATION

Except for air conditioner equipped models Remove two bolts from

I

rear

of

center console

2

Remove center console

by pulling

it back To

3 sole

bracket

tighten

install

properly

insert

the floor

on rear

front

its

center con

portion

into BE033B

and install and

attaching bolts

Fig BF 46 Removing

center console

BF034B

Fig BF 47 Console with

annrest

SEAT SEAT

BENCH SEAT

DESCRIPTION There

are

two

types

of seats

a

semi

separate bench seat for the standard wheelbase and long wheelbase models and

a

separate

seat for the Deluxe Cab

JJ

models

t

CAUTION In

qJ

conforming

302

be

sure

polyethylene cushions

seat

with M Y

s S

No

to remove the thin covers

backs

from

seat

and

head

1

restraints at the time of a

delivery Pre

b Parts

service

2

Seat assembly Seat slide

3

Seat slide lock handle

4

Seat slide lock wire BF474A

replacement

Fig BF 48 Bench 8F 19

seal

Body

Frame


DESCRIPTION

assembly 1

Remove four bolts

slide assembly

to

retaining

seat

floor take out seat

2

To

moval

install seat

reverse

above

re

procedure

s Head re5traint

2

Seat assembly

3

Reclining device

4

Seat slide outer

5

eat slide inner

belt is

three

point type a lap shoulder consisting essentiaily belt and an inner lap belt The lap shoulder belt is fitted with an emergency locking retractor which senses the speed at which the webbing is being pulled and the deceleration of seat

a

of

SEPARATE SEAT

1

The

the vehicle The inner lap belt has buckle of the driver a

s

a

buckle The

seat belt includes

switch which functions as a seat belt

warning device

J

CAlJI10NS a

In

with M V S S

conformity

302

be

sure

polyethylene

to

remove

No

the thin

from seat belts

covers

at the time of

j

I

delivery Pre

2

Parts

service

replacement

b If the vehicle has overturned been

BF0358

entire

Fig BF 49 Separate

seat

c

Remove two nuts attaching front

Remove two bolts attaching of seat slide to floor

Then

remove

seat with seat slides

from the vehicle

of seat slide to floor 2

3

rear

4

Installation is the

reverse

order of

removal

belt

collision

replace regardless

assembly

or

the of

If the condition of any component of a seat belt is questionable have entire belt assembly

replaced

rather

than attempting to repair seat belt d If webbing is cut frayed or dam aged replace belt assembly e

Do not inner

SEAT BELT

a

nature of accident

Removal and installation I

in

f

spill

lap

drinks

belt

oil

buckle

etc

on

Never oil

tongue and buckle Use only a genuine Nissan assembly

seat belt

REMOVAL AND INSTAUATION I


2

Disconnect buckle switch harness

at connector under seat Loosen bolt

3

retaining inner lap lap belt

belt and remove inner 4

Remove bolt securing emergency

locking retractor 5

Remove

and

remove

shoulder

anchor

lap shoulder

belt

bolt assem

bly Installation is the

1

Inner belt

6

2

Tongue stopper Emergency locking retractor Outer anchor plate belt shoulder Lap Shoulder through anchor

removal

3 4

5 6

reverse

Tightening torque Anchor bolts BF036B

Fig BF 50 Seat belt BF 20

2 5 to 3 0

kg

m

18 to 22 ft lb

order of

Body When installing locking retractor make is set vertically

Note

Frame

INSPECTION OF BUCKLE SWITCH

emergency sure

that it

@

The are

g@ I

contacts

normally

latches

the

of the buckle switch

closed

buckle

tongue pushes the

When

tongue tip end of the push rod to open

the switch contacts I


2

Disconnect

buckle

switch wire

harness 3

Using

a

test

switch for proper

light check buckle operation The light

should go out when tongue of outer

lap belt

latches buckle

when it unlatches buckle

and go

Replace

on

belt

assembly if necessary When checking buckle switch operation make sure that power is

Note

held below 16 volts and 13 mA BF650A

Fig BF 51 Seat belt anchorages

8F 21

SECTION BE

BODY DATSUN PICK UP

ELECTRICAL

MODEL 620 SERIES

SYSTEM


LTD JAPAN

BODY ELECTRICAL WIRING

BE

2

LIGHTING AND SIGNAL LAMP SYSTEM

BE

3

METERS AND GAUGES

BE 14

ELECTRICAL ACCESSORIES

BE 21

EMISSION WARNING SYSTEM California models

BE 43

Body Electrical System

BODY ELECTRICAL WIRING DESCRIPTION Cables are covered with color coded

vinyl for easy identification In the wiring diagram colors are indicated by one

letters

alphabetical

two

or

before

disconnected

or

fuse replacement In addition to fuses

has been

installed

battery

performing

other than bulb

any electrical service

fusible link

a

protect wiring The fusible link functions almost the as

same

such

parts

to

though its eharac slightly different than

MAINTENANCE INSTRUCTIONS Fuse

exhaust

as

The

fuse

block is installed under

the instrument

8

Wiring is kept away from any rotating or working parts fan pulley fan belt

panel

the left hand

on

drive vehicle

etc

9

Cables

and

moving parts

between

ftxed portions long enough to vibratory forces

are

withstand shocks and

fuse

a

teristics

temperature

pipe

It is recommended that the

be

6 Each grounding bolt is firmly pbnted 7 Wiring is kept away from any adjacent parts with sharp edges or high

are

normal fuses

Notes Before

a

starting to inspect and repair

any part of electrical system or other parts which may lead to a CABLE COLORS

short circuit

disconnect cables at

battery terminals Cable colors two

are

indicated by

one or

Disconnect

alphabetical letters

B Black

Be

terminal

Brown

G Green

at

positive

R Red

W White

terminal be

The

main

cable is generally coded

with a

single color

coded

with

The

others

two tone

a

cables to battery

connecting

to clean terminals

sure

Fasten cable at

rag

positive

terminal and then ground cable

are

color

at

as

terminal Apply top of these terminals to

When

prevent

Black with white stripe gR Light green with red stripe

b

from

rust

Never

use

a

developing

screwdriver

tool to conduct

c

Inspect all electrical circuits refer ring to wiring or circuit diagrams

use

or

another

systematic

problem before installing

new

a

a

nate cause

of

stalling

fuse

senrice

or

continuity

test

b

an

circuits under

no

12V 3W

or

open circuit

load

Use

a

circuit tester

new

Use fuse of use

Never ground

lamp

If fuse is blown be

fuse

sure

to elimi

before in

problem

specified rating Never

of

more

than

or

specified

rating test Co as

a

load

Check condition of fuse holders If much rust

or

dirt is found thereon

Circuits should be

nuity

or

sandpaper

tional

test

or low reading volt inspection of circuit

lamp

2

often

or

terminal

firmly

in

place

shows

any

and free from rust and dirt

3

No

evidence other 4 away 5

cable

covering

of cracks

deterioration

from Each

any

cable

proper connector

safe distance

adjacent metal parts is or

fastened terminal

to

voltage

drop

or

and could

result in improper circuit operation

FUSE AND FUSIBLE LINK DESCRIPTION The fuse and fusible link

at a

to

in the circuit

or

damage

Each terminal is

lead

heating

Each electrical component part or securely fastened to its con Each connection is

grained

metal to

Poor contact in any fuse holder will

cable is nector

until

proper metal contact is made

that

ensure

I

tested for conti short circuit with a conven

Before

of

fuse

clean metal parts with fine

meter

pro

cause

Notes

on

Use test leads

INSPECTION

reason

one

cedure to check and eliminate

them

BW

for

fuse has melted

negative

grease to

follows

Fuse block

terminal

Before

a

Fig BE 1

cable at negative

Lg Light green

with

BE848A

follows

and then disconnect cable

L Blue

Y Yellow

as

its

are

protec

Fusible link

tive devices used in an electrical cir cuit

When current increases beyond

rated amperage fusible metal melts and the circuit is broken BE 2

Fusible

starting cuits

link

charging

protects and

lighting

accessory

cir

Electrical

Body A

melted

fusible link

be de

can

tected either by visual inspection or by feeling with finger tip If its condition

Notes a

If fusible link should

supply

or

test

circuit

is shorted

questionable use circuit tester or lamp as required to conduct continuity test This continuity test as

be

performed

in the same

carefully

large

current

it

c

is

power

carrying

In such

a

case

check and eliminate

cause

of problem

manner

for any conventional fuse

melt

possible that critical circuit

is

can

System

b

Never

wrap periphery of fusible link with vinyl tape Extreme care should be taken with this link to ensure

that it does not

contact with any other ness

or

vinyl

or

come

into BEB49A

wiring har

Fig BE 2 Fusible link

rubber parts

1

LIGHTING AND SIGNAL LAMP SYSTEM CONTENTS DESCRIPTION LIGHTING

BE

SYSTEM CIRCUIT DIAGRAM

BE

INSPECTION

4

9

BE 10

LAMP

BE

4

BE

5

BULB

BE

5

LAMP BODY

BE

5

8E

7

REMOVAL AND

BE

7

INSPECTION

BE

7

8E

7

REMOVAL AND

BUL8 REPLACEMENT

BE

7

INSPECTION


8E

7

BE

8

BE

B

8E

8

BE

8


BE 11

8E

8

INSPECTION

BE 11

8E

8

8E

8

BE

8

8E

8

TROUBLE

BE

9

CORRECTIONS

BE

9

HEAD LAMP


BE

9

TURN SIGNAL

INSPECTION

8E

9

TAIL LAMP

8E

9

BACK UP LAMP

8E

9

HEADLAMP HEAD LAMP BEAM

REPLACEMENT

AIMING ADJUSTMENT FRONT COMBINATION BUL8

LAMP

REPLACEMENT

REMOVAL AND INSTALLATION SIDE

MARKER

ROOM BULB

LAMP

LAMP REPLACEMENT

REMOVAL AND INSTALLATION REAR COMBINATION BULB

LAMP

REPLACEMENT

REMOVAL AND INSTALLATION LICENSE LAMP BULB

REPLACEMENT

REMOVAL AND INSTALLATION ENGINE

COMPARTMENT

LIGHTING

LAMP

SWITCH

ILLUMINATION REMOVAL

CONTROL

RHEOSTAT

AND INSTALLATION

KN08

ILLUMINATION

TURN

STOP

DOOR

BE 10

REPLACEMENT

SIGNAL

BE10

REPLACEMENT AND DIMMER

SWITCH

INSTALLATION

BE 10

INSTALLATION

BE 10

INSTALLATION

BE 10 BE 11

INSPECTION

BE 11

HAZARD SWITCH

8E 11

UNIT

BE 11

REPLACEMENT

BE 3

BE 10 BE 10

SWITCH

REMOVAL AND

8ULB

BE 10 BE 10

LAMP SWITCH

FLASHER

BE 10

SPECIFICATIONS

BE 12

DIAGNOSES AND BE 12 BE 12 LAMP

STOP

BE 13

LAMP AND 8E 13

Body Electrical System DESCRIPTION LIGHTING

SYSTEM CI RCUIT DIAGRAM

Headlamp tail lamp and license lamp system FRONT SlOE lIIIARI ER LAMP IR H

G

REAR

R 1

jSTOPBrURH STOP 8 TAIL

I R H l

HEAOLAMP

LIGHTING SWITCH

r H

LllHTINIi

1121

I

1

BSAOC

UP

REAR COMBINATION LAMP R H

x

nn

A

TURN

TAIL

f ll lJ

o CR

SIDE

MARKER LAMP

j

DIMMER SWITCH

iNAnON

101

LAMP

USl

LE LINK

LIU

CIl

CJ

I

LICE NSf

J

LAMP

t

ON 0

I

I3

154

CJ

BACIC TA

CJ

FUSE

HEADl AMP

1

lOA

CJ

@

I

r

8A

UP

L

ST OP8TURN TAIL

BLOCK

STOP8TURN

LH

EA LAMP

e H

IL

i

LAMP

I

n

2 IR I

REAR COMBINATION LAMP ILH

METE ILLUMINATION

fMP

Q

REAR SIDE NAR

tAMP

l

BEBSOA

Fig BE 3 Headlamp tail lamp and liceme lamp ay6t Turn signal

hazard warning

stop lamp and back

lamp

m

lamp system

up

REAR COMBINATION LAMP R H

BACK UP LAMP SWITCH

BATTERY

n

TA I L

8ACK

@ 4j

FRONT COM8IfUl1ON LAMP H

@

FUSIBLE LINK

Jl

P W

E

HAZARO FLASHER UNIT

ON

I a h

FRONT COMBINATION LAMP L H

FUSE

HAIARD WA NING SWITCH

2

3

BLOCK

G

FUSE

BACK

FROM IGNITION SWITCH

t

UP

J H

LH

EL

U

STOP 8 TURN

N

t

JTA

STOP8TURN TAIL

CJ

I

TURN SIGNAL INDICATOR LAMP

TU N SIGNAL FLASHER UNIT

r

UP

I

REAR COMelNATlON LAMP IL H I

iH ij STOP

TURN

SIGNAL SWITCH

BE851A

Fig BE 4 Turn signal Juuard warning lamp stop lamp and back up lamp system 4 BE

Body Electrical System Room lamp and engine compartment lamp system

FUSE

BLOC K

1

J QA C

6

I

I

I

2

I

t1

CJ CJ

Wf

fi t ROOM

1

ROOM LAMP

I

I

0

1 SWITCt f

HOOD

LAMP

C o

lA II

BATTERY

ENGINE

I

J CJ C

FUSIBLE LINK

t

100

FUSE

I DOOR

I

I

SWITCH

LH

l

I

c

SWITCHIR H l

DOOR

BE852A

Fig BE 5 Room lamp and engine compartment lamp system

connector from behind beam

HEADLAMP

Note

Rubber

back of

is

cover

headlamp

installed at

beam

The

con

nector is located in the cover 5

Change headlamp

nect

wiring

6

Place

so

that

beam

headlamp

fit

and 8 and

in with

three hollows

on

that

on

sign

upper side

headlamp retaining ring tighten retaining screws Place radIator grille in position tighten retaining screws

lJ

BE300

HEADLAMP BEAM

REPLACEMENT

Note

Do not

disturb

aiming adjust

screws

Remove and

sure

Install

Fig BE 6 Head amp

screws

behind

AIMING ADJUSTMENT

if

I

con

beam in position

three location tabs

mounting ring Make Top of beam lens i 7

beam and

connector to new beam

radiator grille retaining

grille headlamp retaining

It may be unnecessary to

4

2

Loosen three

ring

screws

remove screws

radiator

I 4

3

remove

ii i

Remove

retaining ring by rotating

it clockwise Remove

headlamp

beam

from

mounting ring and disconnect wiring 8E 5

l

1 J i Horiz

tooi 4 Y

nnn

tal adjustment

BE30l

Fig BE 7 Aiming adjustment

Electrical

Body To screw

to

adjust vertical

adjust

screw

on

aim

use

adjusting

upper side of headlamp

on

horizontal aim

use

Keep

a

and

adjusting

on

the same

no

load in vehicle

I Gasoline radiator and engine oil

aimer

an

use

screen or

instructions

operating refer

aiming device headlamp tester of

any

respective operation

to

manuals supplied with the unit

pan filled up to correct levels

in

foUowing

performing headlamp aiming

aiming wall For

See that there is

Before making headlarnp aiming ad the

tester

flat surface

Notes

When

adjustment

b Place vehicle and

c

observe

tires inflated to correct

pressures

side of head lamp

justment

aU

System

2

structions

DRIVING BEAM

HIGH

Without passenger

BEAM

G

L wt

hi

i iiI

H

10 LOW

PASSING BEAM

32 8 ft

m

02 8 n

BEAM

10

W2

m

d

20 I h2 H2

02

10

m

I I

32 8 ft

f

Driving

All models

I

beam

HI

WI

mm

mm

in

in

715

780

28 15

30 71

High beam 01

CO 48

Passing hI

H2

W2

mm

mm

mm

in

in

140 51 5

I

715

28 15

11

beam Low beam

O2

h2

d

0

mm

mm

in

in

in

160

392

45 67

12018

is

349

43

13 74 BE302

Fig

BE 6

BE 8

Aiming adjustment

Body Electrical System FRONT

COMBINATION LAMP BULB

REPLACEMENT

Remove two

1

retaining

screws

and

lens 2

Push in

bulb

on

turn

it counter

clockwise and remove it from socket 3

Insert

bulb into socket press

new

it inward and rotate it clockwise Make sure

that bulb is locked in its socket

Place packing to lamp body in position and install lamp body with 4

lens

packing

and

retaining

two

screws

REMOVAL AND INSTALLATION To

remove

wiring

disconnect

lamp body

at connector and remove wire

grommet from panel Remove two retaining screws and lens and withdraw lamp body from vehicle Install new lamp assembly in the reverse

1

Screw

2

Lens

3

Bulb

4

Lamp body

BE698B

Fig BE 9 Front combinntion lamp

sequence of removal

SIDE MARKER LAMP BULB REPLACEMENT 1

two

Remove

retaining

screws

lens and rim Push in

2

on

clockwise and 3

Insert

bulb

remove

turn

it counter

it from socket

bulb into socket press

new

it inward and rotate it clockwise Make sure

that bulb is locked in its socket

Place packing to lamp body in position and install lamp body with

4

and

lens

packing

retaining

two

screws

REMOVAL AND

2

INSTALLATION To two

remove

remove

from

lamp body

wires

lead

at

wire grommet

disconnect

connectors if so

and

equipped

panel

Remove two

retaining

and rim and withdraw

screws

lamp body

lens from

vehicle

2

Packing Lamp body

3

Rim

4

Bulb

5

Lens

6

Screw

5

BE699B

Install reverse

1

new

lamp assembly

in the

Fig BE IO Side marker lamp

sequence of removal

BE 7

Body Electrical System REMOVAL

ROOM LAMP

AND

INSTALLATION BULB REPLACEMENT

I

wiring assembly

Disconnect

at

cormector

2

Remove two nuts from combina

tion

lamp mounting

3

Dismount

studs

combination lamp

as

from vehicle

sembly 4 Replace lamp assembly

with

a

new one

J

Install

5

reverse

new

lamp assembly

in the

sequence of removal

CD 1

Lens

2

Bulb

3

Lamp body

4

Screw

O lux Cab 8E700B

Fig HE ll Room lamp

LICENSE LAMP BULB

Remove lens from lamp housing Pull bulb forward and

2

remove

it

housing

two wires at connectors

Install

from socket bulb into socket

3

Push

4

Install lens

new

REPLACEMENT

from roof rail and disconnect

reverse

new

in the

lamp assembly

sequence ofremoval

REMOVAL AND INSTALLATION remove lamp assembly discon battery ground cable remove two retaining screws with lens removed from lamp housing dismount lamp

To

nect

REAR COMBINATION LAMP BULB

J i

REPLACEMENT 1

Screw

2

Bracket

3

Lens

4

Bulb

BE702B

Fig HE 13 License Iomp

1

Remove lens retaining

equipped 2 1

Screw

2

Lens

3

Bulb

remove

Pull out bulb and

screw

if so

lens

replace

it with

a

new one

3

4

Rim

5

Lamp body

@

and

BE70tB

Fig BE 12 Rear combination lamp

Install lens

REMOVAL AND I NSTALlATI ON 1

Disconnect

lead

wire

at

con

nector 1

Remove six lens

retaining

screws

it

and lens 2

Push

in

on

counterclockwise socket

3

bulb to

and

remove

turn it

it

from

Insert new bulb into socket

inward

Make

sure

and

rotate

it

press clockwise

that bulb is locked in its

lamp bracket retaining lamp assembly Install new lamp assembly in the Remove

screws

3

reverse

socket 4

2

Place lens into position and install

retaining screws 8E 8

and

sequence of removal

Body Electrical System ENGINE

Removal and Installation

INSPECTION

Test

COMPARTMENT

Remove lighting switch from vehi

LAMP

continuity through using test lamp

switch by

cle following the procedures given in

I

TERMINAL

2 6 terminal

2

Bracket

3

Bulb

SWITCH

P

I

I

4

I

3

I

6

I

T10N

2

F ICI

I

Screw

ohm

meter

I 1

lighting or

b

I

BE 7038

Fill BE 14 Engine compartment lamp

Bulb

can

be replaced by

pushing

in

bulb and turning it counterclock

on

3 terminal

wise 4 terminal

replace engine compartment lamp assembly remove one SCrew retaining lamp bracket to upper dash panel and disconnect wires at connee To

1

terminal

Switch position

BE855A

BE 15

Fig

Lighting switch

tors

Engine compartment lamp switch be replaced by disconnecting lead

ILLUMINATION

tion

CONTROL RHEOSTAT

heater

can

wire at connector and

assembly

switch

pulling

out of its bracket To install

This illumination control rheostat controls the brightness of the iliumina

switch assembly to bracket clean dirt dust and rust from the opening groove of bracket and press down on switch

lamps

of the combination meter

control

wiper

switch knob

it

and its

can

value

is

a

and

lighting

variable resistor

be controlled

by

a

knob

head until it fits in with bracket

0@

LIGHTING SWITCH REMOVAL AND

BE 7048

INSTALLATION I

Disconnect

2

Press

in

Fig

battery ground

switch knob

counterclockwise and

pull

it

out of

REMOVAL AND

INSPECTION

INSTALLATION Test

switch 3

Unscrew escutcheon and escutcheon and spacer

remove

I 2

Remove ring nut retaining switch

meter

to instrument

multiple

at connector

from

instrument

harness wiring assembly and spacer and lighting switch 5

Install

new

remove

switch in the reverse

sequence of removal

3

4

panel

Disconnect lead wires for switch

Switch

a

When

test

lamp

or

two lead an

ohm

switch is in the OFF

position continuity must not exist In the ON position resistance between the two lead wires must be between 0

body

can

be

taken out

from behind instrument panel 5

continuity between

Pull out knob of switch

wires with

Reach up from underneath instru ment panel disconnect lighting switch

4

connector

rhe08tat

cable

turn it

BE 16 Illumination control

Installation

is in the

quence of removal BE 9

reverse se

and 3512

Body Electrical System KNOB ILLUMINATION LAMP The illumination lamp

is located on

2

clip

Unhook

7

Tighten

that

8

Install shell

9

Connect

wiring assembly from retains wiring assembly to

panel

lower instrument

multiple

Disconnect

3

and lead wire from instrument harness

This lamp illuminates the knob of the wiper switch and lighting switch

wiring

with

fiberscopes

screws

multiple

connector and

10

Clip wiring assembly instrument panel II

Upper and

Remove shell covers

4

attaching

covers

lead wire to instrument harness

connector

the illumination control rheostat

two

wiring lower

at

Install steering wheel

Lower

The fiberscopes between the knobs and cap of the illumination lamp carry the light through their tubes with the inner reflective walJ

5

Loosen

two

switch assembly

screws

attaching

steering column jacket and remove switch assembly 6 Position switch assembly to steer ing column jacket Make sure that a location tab

to

or

screw

INSPECTION

ohm

or

meter

hole of steering column jacket 3

lighting

continuity through using test lamp

Test

switch by

fits in with

terminal 4 terminal 7 terminal

Dimmer

CID 1

Bulb socket

2

Screw

3

Lamp body

8E705B

Fig BE 17 Knob illumination lamp

BULB REPLACEMENT Ll

Reach up from under the instru ment panel and pull out socket with

I

bulb from

12

I

2

j

lamp body

Pick up bulb and install

a

I

new

one

3

Installation is in the

reverse

4JN l ER

R

se

quence of removal

r vt

I RI

PlOSITlON

L

n

LASH STOP

I I

91

9

I

I

JFRe

II

L I I

III

I

61616

11

161

II

I

BE706B

LAMP

Remove

1

Fig BE IS Turn signal and dimmer switch

BODY REPLACEMENT illumination

rheostat Refer

to

control

section of illumina

2

illumination

lamp

Remove

3

body can

4

lead

Disconnect

wires

for

at connector

leased

REMOVAL

open On the contrary contacts closed with plunger projected

AND

retaining lamp panel Lamp body

then be taken out

easily


reverse

se

quence of removal

Stop lamp switch bottom of

pedal

is mounted at the

Door

I


2

Disconnect lead wires at

REMOVAL AND

DIMMER SWITCH

4

Steering

both

on

coonee

Loosen lock nut unscrew switch

assembly

and

Install

remove

switch

switch

assembly

assembly

as

de

scribed under Brake Pedal in Section BR

INSTALLATION I

Disconnect battery

2

To

lower 3

When

assembly

pull pillar

ground

switch assembly withdraw

cable out

switch

of

and

wiring assembly

INSPECTION section

switch is installed

H and R H front door pillars L

TURN SIGNAL AND


DOOR SWITCH

bracket

3

Remove steering wheel related Refer to the

are

and steering post

tors

I

stop lamp switch

INSTALLATION

screw

to instrument

contacts are

STOP LAMP SWITCH

ti on control rheostat for removal

plunger

Disconnect lead wire at

cannee

tor

is pressed into switch

when brake 8El0

pedal

is

reo

4


quence of removal

reverse se

Electrical

Body INSPECTION Test

continuity

switch by using

test

door through lamp or ohm

2

Remove shell covers

3

Remove

assembly

door

open

Contacts

plunger

is

is

pressed

switch are

into switch

contacts

Upper attaching

Install

verse

There are two flasher units One is for

hazard

switch

in the re

signal

turn

and the

other

for

hazard

sequence of removal

They

are

located

at both sides of

panel near steering column They can be distinguished from each other by their shape The large one is for turn signal the smaller for hazard See Figure BE 20

are

instrument

when

closed

FLASHER UNIT

screws

switch 4

plunger

two

switch to lower shell cover and remove

meter

When

System

projected

HAZARD SWITCH

INSPECTION Test

REMOVAL AND

switch

INSTALLATION

continuity through by using test lamp

hazard or

ohm

meter 1

Disconnect

multiple

connector

and lead wire from instrwnent harness

wiring

I I I

ON

7 terminal

TERMINAL

SWITCH POSITION

ON

OFF

li

2

I

5

I

4

I

5

I I

8

ill

1

Hazard flasher unit

2

Turn

signal

flasher unit

BE707B

Fig BE 20 Flasher unit

I

7

REPLACEMENT

To flasher unit 1

3 terminal

4

terminal

I

Disconnect

2

Disconnect

connector

fitted

to

bottom of unit

terminal

3 5


terminal BE308

6 terminal

4

Fig BE 19 Hazard switch

BE 11

Remove

screw

retaining flasher

unit


quence of removal

reverse se

Body Electrical System BULB SPECIFICATIONS Bulb Item

Wattage Candlepower

4001

5W 37

Inner

Headlamp

SAE trade number

4002

5 S0W 37

Outer

Front combination lamp Turn

signal and parking lamp

1034

23 8W 32 3C

Side marker lamp Front

8W

Rear

8W 4C

lamp signal lamp A Tail lamp B C

67

4C

67

Rear combination

B

Turn

A B

Stop lamp Back up lamp D

A

23W

32C

1073

B

23j8W

32j3C

1034

C

8W

4C

D

23W

32C

7 SW

License plate lamp

Engine compartment lamp

6W

Room lamp

5W

Combination meter illurnina

iC 17W

tion

Knob illumination lamp Heater control illumination

89

6C

161

x3

3 4W

2C

158

4W 3

2C

158

lamp

TROUBLEDIAGNOSE

67 1073

AND CORRECTIONS

HEADLAMP Probable

Condition

Headlarnps do

not

light for both high and low beams

High beam

cannot

Corrective action

cause

Burnt fuse Loose connection

or

open circuit

or

vice versa

replace fuse

Check wiring and

or

repair

connection

Faulty lighting switch

Conduct continuity test and

Faulty dimmer switch

sary

Faulty light relay

Check light relay for proper operation and replace if necessary

No ground

Clean and

Faulty dimmer switch


tighten ground

replace

if neces

terminal

replace

if neces

sary

be switched to low

beam

Correct cause and

Check light relay for proper operation and replace if necessary

Faulty light relay

BE12


Condition

Probable

Partly discharged

Headiamps dim

or

Corrective action

cause

faulty battery

Measure

Faulty charging system

specific gravity of electrolyte and replace battery if necessary

recharge

or

Measure

voltage

If

it

is

less

at

headlamp terminals

than

12 8V

check

charging

system for proper operation Poor

Clean and

loose connection

ground or

side

in

only one

lights

headlamp

Loose

tighten

Replace

Burnt sealed beams

Headlamp

or

connection

Repair

Damaged sealed beam

Replace

TURN SIGNAL LAMP Probable

Condition

Turn not

signals

Corrective action

cause

Correct

Burnt fuse

do

operate

Loose connection

Faulty flasher Faulty

turn

or

Check

open circuit

wiring and

or

repair

connection

Replace

unit

signal

and replace

cause

Conduct

switch

continuity test

and

replace

if

neces

sary

Flashing cycle

is

too slow

not go

having wattage other

wattage

lamp

Pilot

Bulbs

out

does

are

than

specified

Replace

with

specified

one

with

specified

one

used

Burnt bulbs

Replace

Loose connection

Repair

or

too fast

Inoperative flasher

Flashing cycle irregular

is

Burnt bulb

Replace

Loose connection

Repair

Bulb wa

TAIL LAMP

having wattage

other

than

specified

Replace

ttage is used

STOP LAMP

AND BACK UP LAMP

Probable

Condition

Both right and left lamps do not light

Replace

unit

Corrective action

cause

and

Burnt fuse

Correct

Inoperative stop lamp switch


cause

replace replace

if neces

sary

Conduct continuity test and replace if neces

Falllty back up lamp switch

sary

Loose connection

Lamp lights

in

only one side

or

open circuit

Check wiring and

or

Burnt bulb

Replace

Loose bulb

Repair lamp socket

BE13

repair

connection


METERS AND GAUGES CONTENTS COMBINATION METER COMBINATION METER

BE 14

CHARGE

CIRCUIT

WARNING LAMP

DIAGRAM

BE 14


BE 16

DESCRIPTION

BE 16

HAND

SPEEDOMETER REMOVAL AND

INSTALLATION

ODOMETER SWITCH REMOVAL AND INSTALLATION FUEL GAUGE

AND

WATER

HAND

METER

AND WARNING

8ULB

BE 18

SWITCH

ILLUMINATION

REMOVAL

LAMP

BE 18

BRAKE

BE 16 8E 16

BE 17

BRAKE WARNING

BE 16

TEMPERATURE

GAUGE

BE 17

DESCRIPTION

8E 18

INDICATOR

BULBS

8E 18

AND INSTALLATION

BE 18

BE 16

TROUBLE

DESCRIPTION

BE 16

CORRECTIONS

REMOVAL

BE 16

SPEEDOMETER

8E 17

WATER TEMPERATURE AND FUEL

AND INSTALLATION

OIL PRESSURE WARNING

LAMP

DESCRIPTION 01 L

PRESSURE

SWITCH

BE 18

SPECIFICATIONS DIAGNOSES AND

BE 18

BE 17

GAUGES

BE 17

OIL PRESSURE

BE 18

BE 19 AND CHARGE WARNING

LAMPS

BE 20

COMBINATION METER Meter illumination lamps

COMBINATION METER Turn

CIRCUIT DIAGRAM

signal

indicator lamp L H

9

9

R H

iJ O

l I

rl8 i g

o

J

OIL

sq nal

indicator lamp

J

lL Tj

I

M T only Turn

Voltage regulator CHG

TEMP

0

0

BEAM

BRK FUEL

C

Q

Speed

switch

BE856A

@

I

Speedometer

2

Thermometer

3

Fuel

4

Tachometer

5

Cluster lid

6

Speedometer cable Speed switch amplifier Manual transmission only

7

meter

Option

BE6828

Fig BE 21 BE 14

Cuit Ci1

diagram of combination meter

Body

Electrical

System

Circuit diagram of combination meter system

IGNITION SWITCH BATTERY

1 lOA 0 FUSIBLE

LINK

r

G

0

r

g

KG I

I

lOA

r

15A

t

15A

i

Jon

HAZARD FLASHER

0

j

UNIT

J L

Z a

l J J I IIl ll Z ll Z LlJ LlJ J a J a

Z2 lIa I LlJ IZ

J

Z az

Z J z

i

g

o I

a ll

I

I

1 1

5a

7

LlJ I

B

z

aa

I

00 a a LlJLlJ ll ll a a

u

I

I

2

I

I

3

I

J

D

14

LIGHT

61 6

I 5 16

RELAY

i2i

I

9 76

mm

S e

ONI

I

02

u3

OFF

l I

o

FUEL TANK

HAZAR D SWITCH

I

04LlJ

l1

S M

ii

I

a Zza

FROM AMP

J

I

FLASHER UNIT

l1 l1

CJ

J

J 00

TURN SIGNAL SWITCH

LlJLlJ z z

B COO CUT

SOLENOID

I lFLA

n

i

OIL

PRESSURE SWITCH

IR

R

IR

L

IF IF

R

f

THERMAL TRANSMITTER

a

I

VOLTAGE REGULATOR

HAND

FROM

BRAKE

RELAY

SWITCH

J

LIGHT RELAY TERMINAL TO

L

L

RI I

I I u u

I I

L1GHT DIMMER SWITCH

IOFF

21

l B

I I I

X X

LIGHT

SWITCH BEB57 A

Fig BE 15

BE 22 Circuit diagram of combination meter ayatt

m

Body Electrical System REMOVAL AND

2

INSTALLATION

shadow

cover

and

plate by removing clips

and

Remove meter front

screws

I

Disconnect

battery ground cable Working through meter openings

2

of cluster

cluster

retaining panel 3

lid

remove

From

lid

three

screws

instrument

to

underneath

3

The water temperature gauge con a gauge and thermal transmit

sists of ter

Remove

located in the engine block

thermal transmitter is

equipped

printed circuit housing and remove speedometer 4 Install speedometer in the reverse

thermistor

which

sequence of removal

tr

screws

retaining speed

ometer to

cooling a

element

water

and

ture gauge are arm

follow

etc

the

the procedures given in each section 5 From behind combination meter

ODOMETER SWITCH

disconnect

REMOVAL AND

cable

speedometer

at

speedometer head and multiple con nector instrume nt wire assembly from printed circuit 6 On vehicle with clock disconnect wires

at

printed 7

connection

on

meter

circuit

assembly

Remov

screws

retaining

to cluster lid

combination meter

ter

When

is

INSTALLATION I

Remove

under 2

speedometer

installing

assembly

follow the

reverse

a

bi metal

bent

and thus

the bi metal the

pointer

gauges are the same A tolerance may

odometer

retaining

temperature gauge source voltage fluctuation The voltage regulator is used to supply a constant

screws

Install

and the heat coil is this heat

outlined

as

Speedometer

Remove

coil

With

odometer in the

reverse

voltage

sequence of removal

so

the water

occur on

or

fuel gauge due to

that the water

temperature

gauge and fuel gauge operate The operating part of the

as

consists of

combination

provided with

connected to the bi metal arm is oper ated The characteristics of both

sembly 9

heat

heated arm

3

four

Remove

me ter

8

each

to

and heater coil When the ignition switch is set to ON current flows to

Withdraw cluster lid slightly For to switches knobs

thermal

The fuel gauge and water tempera

ment

ccess

the

the gauge

instrument

panel remove one screw retaining me ter assembly to lower panel of instru 4

thus

rtrols cUfTent flowing

c

t

converts

variation to

temperature

resistance

The

with a

coil

me

turned on

se

quence of removal

a

When

and

bent

contact is

coil cools

correctly regulator

bi metal arm and a heater

the

ignition

switch

is

the bi metal arm is heated

by the coil

Consequently interrupted

opening the current to the

As

the bi metal

the contact closes

The repeti

tion

of this operation produces a pulsating voltage of 8 volts which is applied to the water temperature and BE342A

Fig BE 24 Odometerswitch

fuel gauges If both

to

Fig

BE 23

Removing

the

water

temperature

gauge and fuel gauge become faulty at the same time this may be attributed

problem in the voltage regulator

eluster lid

FUEL GAUGE AND WATER

REMOVAL AND

INSTALLATION

TEMPERATURE GAUGE

1

Remove

combination

meter

as

sembly Follow the procedures under Removal and Installation in Combina

DESCRI PTION

SPEEDOMETER

tion Meter

The fuel gauge consists of

REMOVAL AND

Remove combination

meter as

Follow the procedures under Removal and Installation in Combina

sembly

tion Meter

tank

2

Remove meter front

cover

unit located in the fuel tank and fuel

shadow

The tank unit detects fuel level with its float converts fuel level varia

screws

tion to

back side of combination meter

gauge

INSTALLATION 1

a

installed

a

resistance of slide resistor

on

the float base

controls current

flowing

and thus

to the

fuel

3

Remove

sembly and 4

retaining

remove

BE16

nuts

at

the as

meter

Install meter in the

quence of removal

gauge

and

plate by removing clips and

reverse

se

Body Electrical System Fuse

M

OIL PRESSURE SWITCH Meter

voltage regulator

To

YR

lffi YW

l

B

f

Ignition

r@

switch

1

Water temperature gauge

oil pressure switch dis

replace

connect

lead wire from switch termi

nal and

unscrew

switch from engine

cylinder block Prior to block

Fuel gauge

Y

installing

be

to

sure

switch to cylinder conductive

apply

sealer to threads of new switch

Fusible

I

link YW

t L

Thermal transmitter

Fuel tank BE261

Fig BE 25 Circuit diagram offuel gauge and

kg

cm2

psi

CHARGE WARNING LAMP

is

and

oil

reaches

the

DESCRIPTION

above

pressure the circuit opens and the light

range

charge warning lamp glows ignition switch is set to ON with the engine shut down or when the generator falls to charge with The

when

goes out

BOX YR

SA IGJ

4 to 0 6 0

Under normal opera

stationary the ligh glows with the ignition switch turned on When the e gine is running

whenever engine oil

FUSE

5 8

when the engine tion

The engine lubricating system in corporates an oil pressure warning

glows

7to

5

DESCRIPTION

which

temperature gauge

pressure falls below

OIL PRESSURE WARNING LAMP

lamp

water

the engine

TO METER VOLTAGE REGULATOR

I

G

TO OTHER lAMPS

G

ON

the charge warning and

closed

the

flows from

current

Fig

YB

YB

rent

opposes th

current

is

into cur

flowing

from the warning lamp as the current N increases the solenoid is more

FROM

tl

PRESSURE

N

comes

the generator output

operation

BATTERY

When the engine

BE 27 1

started and the generator

FUSIBLE LINK O J BROWN

Fig

is set to circuit is

ignition switch to the warning lamp and grounds through the regulator

Oil PRESSURE

BE 26

ignition switch

WARNING

WARNING LAhlP

I

operated

When the

jt

IGNITION SWITCH

the

energized

PRESSURE

and

the

pilot lamp relay

contacts are open in effect it oreaks the warning circuit ground connection

BE263

and the lamp goes out

Circuit of oil prelSure warning system

Fig BE

27 2

Fuse box

Fuse box M

Fusible link

From

From battery

battery swllch

ru

A

To ignition

T

tI

I

J v

coil

ge it

WR

IQlamps

r

Charge warning lamp

j

f

lamp relay

War I

e

g

bt

Generator

Fig BE 27 1

YR other

ft t

r L

warning

hr

witch

i J

To other

A

i Generator

YR

nu

J

T

I

M

Ignition

To battery

Ig ition

To battery

Fusible link

Glj I

fCOil

UTO

warrung

ignition WR

Warning lamp relay

lamps

Charge

warning lamp

BE264

Voltage regulator

Fig BE 27 2

Circuit ofcharge warning system

BE17

Body Electrical System HAND BRAKE SWITCH

HAND BRAKE WARNING LAMP

To

remove

METER

hand brake switch dis

ILLUMINATION INDICATOR AND WARNING BULBS

lead wire pull switch out of hand brake control bracket and with connect

DESCRIPTION The hand brake

draw switch and wiring assembly

warning lamp glows

when the hand brake is

REMOVAL AND

applied

When the ignition switch is set ON

current flows from the

INSTALLATION

to

ignition

To

switch to the warning hand

lamp When the applied hand brake

is

brake

replace

bulb

turn bulb socket

counterclockwise to dismount it from combination meter

warning switch is closed and warning lamp glows

connect

lead

wire

printed

circuit

and

if necessary dis connector from remove

bulb from

socket Fuse

Ignition

M

5

BULB SPECIFICATIONS

I

tch

SAE Trade

Item

Bulb No

Wattage Candle power W

Fusible link

Meter illumination YG

1

From battery

1

Hand brake sWitch BE314

Fig BE 28 Circuit of hand broke

indicator

161

7I 1

161

7 1

I

17

I I

signal

High

beam indicator

lamp

161

Oil pressure warning

lamp

161

I 7

Charge warning lamp

161

7 1

I

Hand brake warning

158

34

2

158

4 3

2

Clock illumination

lamp

lamp

lamp

E DIAGNOSES AND CORRECTIONS

SPEEDOMETER Condition

Probable

Speedometer pointer

Loose speedometer cable union nut

and odometer do not

Coirective action

cause

Retighten

Broken speedometer cable

Replace

operate

Damaged

speedometer

drive

pinion

gear

Replace

Transmission side

Inoperative speedometer Unstable speedometer

Improperly tightened

pointer

cable union nut

Unusual sound

occurs

in response to in crease

in

driving speed

or

Replace loose speedometer

Retighten

Faulty speedometer cable

Replace

Inoperative speedometer

Replace

ExceSjvelybent

or

cable inner wire

lack of lubrication

or

x3

Turn

warning Iystem

TROUB

lamp

e

twisted

speedOmeter


Replace Replace

8El8

or

lubricate

Electrical

Body

Probable

Condition

Inaccurate speedometer

System

Corrective action

cause

Replace


indication

Inaccurate odometer

Improperly

operation

worn gears

meshed second and third gear

Replace speedometer

to deformed odometer

Replace speedometer

Faulty feeding due and pinion carrier

WATER TEMPERATURE AND FUEL GAUGES

Probable

Condition

Both water temperature gauge and fuel gauge

Corrective action

cause

Correct cause and

Burnt fuse

Inoperative

gauge

voltage regulator

replace

fuse

Replace

water temperature gauge

Replace

water temperature gauge

do not operate

Both water temperature gauge and fuel gauge

Inoperative gauge voltage regulator pointer fluctuates excessively

indicate

Loose of poor

inaccurately

Gauge

Gauge pointer

connection

Correct connector contact

fluctuates slightly Correct

conn

Water temperature gauge Water

temperature

Faulty thermal transmitter

gauge does not

connection

operate

When wire is

Faulty

loose terminal

thermal

Replace

transmitter

or

correct

terminal connection

thermal

grounded water

or

yellow

transmitter

white

gauge pointer fluctuates

temperature

gauge

Replace

wtater

temperature gauge

Open circuit

Gauge indicates only maximum

temperature

Water temperature gauge does not

Faulty thermal transmitter Gauge pointer returns to original position when ignition switch is turned off

Replace thermal transmitter

Faulty water temperature gauge Gauge pointer indicates maximum tempera ture even after ignition switch is turned off

Replace

Faulty water temperature gauge Faulty thermal transmitter

water

usn resistance between ther wire and transmitter yellow white

Connect mal

temperature gauge

a

ground When gauge indicates

operate accurately

500C Loose

or

i220F

approximately

gauge is serviceable

Correct gauge terminal contact

poor connection

BE 19


Probable

Condition

Corrective action

cause

Fuel gauge Fuel gauge does not

Faulty tank

operate

connection resistance

F

unit

Replace tank

or

correct terminal con

a

half level when

a

35U

ground fuel gauge

Replace

Poor or loose cormection

Conect connector terminal contact

circuit

pointer

unit E

lowers below

tion switch Is turned

unit

Replace fuel

gauge

position when off

F

ignition switch is turned

AND CHARGE WARNING Probable

Condition

Replace tank mark when igni

off

Faulty fuel gauge pointer still indicates

OIL PRESSURE

terminal

is connected between tank unit

wire and

Faulty tank

position

unit

Faulty fuel gauge

Open

Pointer indicates only

loose

or

nection

indicates

pointer yellow

unit

LAMPS Corrective action

cause

Oil pressure wamiug

lamp Lamp does not light when ignition switch set to

oil pressure switch switch terminal connection

Inoperative is

When

ON

switch

yellow

black wire is

or

loose

Replace

switch

OJ

correct terminal connee

tion

grounded

warning lamp lights Burnt bulb

Open Lamp does not go out while engine is being

operated

or

Replace bulb

loose bulb

or

correct bulb socket

circuit

Lack of engine oil

Check oil level and add oil

Oil pressure too low

Inspect engine oil pressure system

Inoperative oil pressure switch

Replace

oil pressure switch

Burnt bulb

Replace

bulb

as

required

OIarge warning lamp Lamp does

not

light

when ignition switch is set to

ON

loose bulb

Warning lamp regulator white Open

Lamp does not go out when engine is started

or

does not

light

or

correct bulb socket

when voltage

red wire is grounded

circuit

Inspect charging system

Faulty charging system

BE 20


ELECTRICAL ACCESSORIES CONTENTS HORN DESCRIPTION REMOVAL

AND INSTALLATION

IGNITION SWITCH REMOVAL

AND INSTALLATION

HEATER

BE 21

FAN

BE 21

CONTROL ASSEMBLY

8E n

ADJUSTMENT

BE 22

SPECIFICATIONS

BE 22

INSPECTION WINDSHIELD WIPER

INSPECTION INSTALLATION

REMOVAL AND

ADJUSTMENT CLOCK

BE 29 8E 29

BE 30 BE 30 BE 30

30 8E

REPLACEMENT

8UL8

BE 23

RADIO

BE 29

REPLACEMENT

BE 23


CORE

MOTOR

TACHOMETER

BE 23

AND WASHER

8E 29

BE 21

SEAT 8ELT WARNING

8E 31

SYSTEM

BE 31

BE 25

DESCRIPTION

BE 25

REMOVAL

AND INSTALLATION

BE 31

BE 25

WARNING

LAMP BULB REPLACEMENT

8E 31

BE 25

INSPECTION

8E 31

DIAGNOSES AND

REMOVAL

BE 25

TROUBLE

I NST ALLATION

BE 26

CORRECTIONS

BE 33

BE 26

HORN

8E 33

DESCRIPTION

BE 26

WINDSHIELD WIPER AND WASHER

8E 34

AIRFLOW

BE 28

RADIO

BE 35

HEATER

HEATER

BE 29

UNIT ASSEMBLY

HORN

horn button

flow

horn circuit includes

a

horn

relay Current from the battery flows through the fusible link and fuse to the horn relay terminal B where it is shunted by the two circuits In one circuit

terminal S

supplied

through

ground

supplied through

is

horn

contacts

and

serves as a

grounding

the

relay

is

pressed

battery energizes the

energized

closed

This

the

the

allows the current to flow to the horn

solenoid

and

contacts

INSTALLATION Horn

bracket

the current flow is

relay

REMOVAL AND

I

As the solenoid is

solenoid

the

Horn

When the horn button current from the

In

the current

other circuit terminal H

DESCRIPTION The

the

to

are

2 on

Disconnect battery ground cable Disconnect horn wire at terminal horn

body

3

Remove horn

retaining bolt

4

Install

in

horn

the

reverse

se

quence of removal Horn relay The horn

Fusible link

H

Qi

Fu

att

Horn button

Qm

J t JJI

L

is installed on the

3

Remove retaining

4

Install horn relay in the

sequence of removal

HIBQ I

relay

hoodIedge on the right side of the engine compartment I Disconnect battery ground cable 2 Disconnect horn relay wire con nector at terminals on horn relay

J

Hornrelay BE859A

Fig BE 29 Circuit diagram of horn sy tem BE 21

screws reverse


1

Voltage regulator

2

Horn relay

3

Headlamp relay Ignition relay California only heater relay choke Auto Compressor relay Au conditioner equipped model Floor sensor relay California only Inhibitor relay Automatic tran5mission only

4 5

6 7

8

BE683B

Fig BE 30

Horn switch

INSPECTION

The horn switch is

signal

turn

integral with

the

switch

and dimmer

Remove switch assembly

sembly

Test

as

and Dimmer

Signal

outlined in Turn

ContInuity test

as

switch

continuity through ignition by using test lamp or ohm

meter

Switch

BE861A

Fig

BE 3 I Removing

ignition

switch

IGNITION SWITCH REMOVAL AND INSTALLATION

C

cable

ground

I Disconnect battery from battery 2

Unscrew and

remove

escutcheon R terminal

from the front of ignition switch Withdraw ignition switch 3

wiring assembly 4

Disconnect

from

with spacer

Figure

shell cover as shown in

wiring

and

BE

1G terminal TERMINAL

connector

A terminal ST terminal

switch

from the back of ignition 5 Replace ignition switch with

KEY

FOSITlON

0

A

F F

C C

B terminal a

B

1

o

IG new one

6

Connect

ignition

switch to

ignition

switch to shell

ST

wiring

Position

cover

u

A

connector 7

opening

escutcheon and

install secure

and

t

3

R

tighten

u

j

I I

BE6848

ignition switch Fig

to shell cover

8E 22

BE 32 Ignition

witch

Body Electrical System Washer pump

WASHER

WINDSHIELD WIPER AND

The washer pump and washer fluid are integral parts and are serviced


tank as

assembly

an

Caution for windshield waBher

operation I Be

only washing solu

to use

sure

tion Never

mix

use

powder

soap

or

detergent with solution 1

2 3

Windshield wiper blade Windihield wiper arm

5

Wiper motor Wiper motor bracket Connecting rod

6

Pivot

4

2

Do not

operate windshield washer continuously more than 30 seconds or

without

Fig BE 33 Wind hield wiper

er

should be

less at I

and

2

Remove

Remove cowl

top grille See Sec

tion BF 3

Remove cowl

top grille 3 Remove stop ring that connects wiper motor arm to connecting rod 3

Remove two

flange

nuts

retaining

pivot wiper linka e to cowl top Remove stop ring that retains 4 connecting rod to wiper motor arm 5 Remove wiper motor linkage as sembly 6 Install wiper motor linkage in the reverse

I

From

disconnect connector 4

under

panel

instrument

wiper on wiper

Remove

motor motor

three

harness

at

Install

retaining

screws

wiper

motor

tank

and motor

reverse

sequence of

Install washer

4

the

in

removal Washer nozzele

sequence of removal

Access for washer nozzle removal is

obtained by disconnecting vinyl tube and removing washer nozzle retaining from cowl top When washer nozzle is installed

screw

washer

fluid

fluid is

sprayed

Figure BE

assembly

Removing wiper linkage

wiper

arm

in correct

and

blade

sweeping angle

See Figure BE 35 for correct

installing

dimensions

I 25 mm 0 984 in

j217

Press

in

switch

counterclockwise and

knob

pull

turn it

Unit

Unscrew escutcheon and remove

disconnect wiper switch

panel multiple connector

Fig BE 35 Wip

J

from

instrument

harness wiring assembly and

remove

arm

irutallation

4

Install

new

nun

in

BE863A

BE 37 Waaher nozzle adjuatment

Fif

INSPECTION Wiper motor I

Disconnect

wiring

connector

from wiper motor

spacer and switch BE862A

J

out of

switch

ment

i

r l

450 1772

it

escutcheon and spacer 3 Reach up from underneath instru

r

that washer

in range indicated in

1

1

2

JC

sprayed

direction by

Ii 1 00 Li L L 1 3 94

270 to 63

Wiper and washer switch

so

not

or

37

450 72

Fig BE 36

is

nozzle

adjust

bending nozzle tube

Install

pump

from tank bracket

assembly

properly

7

washer

two

Pull out washer tank and motor

3

in the reverse

sequence of removal

BE 34

or

Remove hose from washer pump

when

Fig

10 seconds

operated

and drain washer fluid

assembly

body

and pull out wiper motor forward 5

washer

time

one

Disconnect

2 arm

often

This

windshield

lead wires at connectors

Wiper motor

wiper blade assembly from pivot I

fluid

operation Normally windshield wash BE685B

Wiper linkage

washer

improper

causes

switch in the

sequence of removal BE 23

reverse

2

Connect test lead between B ter

minal

on

motor

ide and

battery posi

Body Electrical System tive terminal

or

B terminal and blue

red wire terminal in wiring connector

plug 3

To check wiper low

tion

speed

L terminal to

connect

with ground cable

or

opera Blue white

ground

connect L termi

nal to black wire terminal

make

sure

that wipers sweep at low speed 4 To check wiper high speed opera tion connect

nal in the

to H termi in

3

step

that wipers sweep fast During low speed operation

make 5

ground cable

same manner as

sure

nect E terminal to

con

H tenninal

o

ground and conlect

@

P and L terminals with lead wire as

shown in Figure BE 38 At this time make sure that auto stop mechanism to stop wiper blade at the position specified 6 Wiper is in good condition if actuates

above tests are made

as

C BE864A

indicated

Fig BE 38 Wipftrmotor Fusible link

e

Cl

rt

Battery

Wiper and washer switch Ignition

witch

Continuity test Remove wiper switch from vehicle as

WQ5hcr motor Fuse

I

motor

Wiper B

LR

I

191

switch by

O Y

Dj Wiper

box

terminal

y

P tenninal

L

L terminal

w

H

I

rmjrW

t

r

r

J

using

test

lamp

wiper

or

ohm

meter

switch

1 21

b

E terminal

outlined in Wiper Switch Test continuity through

1

I

II BE865A

Fig BE 39 Circuit diagram of windshield wiperwtUher

TERMINAL

I SlOIT01 I OFF

POSIl10N 2

I 2

I

Z I

Z

I

te7tl

I

1

b

sy

ii I

I

I

I

10 I

I

2 4

5

Switch position

m

3

2

BE686B

Fig 8E 24

40 BE

Wi

r

witch

Body 2

RADIO

Electrical

Remove

System

holding

radio

nuts

and

washer from radio control shafts

REMOVAL AND

3

INSTALLATION

front of radio

Remove

4

Radio

From

disconnect

Removal

5

under

bezel

Remove

from

cable

radio

from

lead

and

and speaker

the

panel

instrument

antenna

power lead

wires

Pull radio knobs offradio control

radio

t

lead

instrument

panel

shafts

BEB67 A

Fig BE 42 Radio ant

nna

ADJUSTMENT Antenna trimmer When or

a

new

radio receiver antenna

Extend 2

Tune

tween on

completely

antenna

in the weakest station be 1 200 to 1 600KC

12 and 16

dial

regard

but dis

generated

it

Turn

trimmer

antenna

and left slowly and set it at aE323

antenna

adjusted

Noise may be

3

installed

antenna feeder is

trimmer should be

right position highest

to a

where receiving sensitivity is

Fig BE 41 Radio

Installation

Installation

panel panel

m behind Fr position radio to instrument

2

Install radio bezel to the front of

3

Install washers and nuts

control shafts and

tighten

on

them

radio

secure

pillar

Connect antenna cable and lead

wires power lead and

vehicle that is not

2

with SE133

Thread mounting stud of antenna

clip opening 3

speaker lead

equipped

radio

into

ly Then install control knobs 4

antenna

on

radio

plugs that cover mounting opening in front when installing radio antenna

Remove rubber

instrument

upper

antenna

Fig BE 43 Adjwting

antenna

trimmer

mountins

Insert antenna cable into

lower

mounting opening and place nna base in position Install antenna base retaining

antenna ant 4

Removal From

behind

instrument

disconnect antenna cable at 2

Remove

remove

3

pillar

on

Remove

retaining

antenna ont fr

5

Route antenna cable

dash

panel

6

Connect

and

antenna

nector

upper

Remove battery 2

cable

at con

Remove

instructions in

ground

cluster

steps

lid

cable

following

I to 4 of Removal

in Combination Meter

tor

3

of

screw

cable

along

to radio

antenna base and

antenna base

sembly from 4

plug

panel

conne

REMOVAL

screw

Antenna and antenna cable

CLOCK

Disconnect three wire connectors clock

printed

as

from

combination

meter

circuit and instrument harnes

wiring

pillar

4

Unscrew antenna clip from front

Remove three

s rews

clock from cluster lid

if necessary BE 25

and

remove

Body Electrical System INSTALLATION I

Position

install three 2

clock

cluster lid and

screws

Connect three wire connectors of

clock

to

each

connection

combination meter to instrument h 3

to

printed

ness

Install cluster

two

to

circuit one

wiring

lid to instrument

panel 4

Connect battery

ground

cable

Fig BE 44 Clock

HEATER DESCRIPTION

@

Defroster nozzle L U

7

Ventilator knob

2

Deflortcr duct LR

8

Heater

3

Heater

9

4

Resistor

10

Conuol cable clip Heater cock

5

Heater motor

11

Defroster duct

Heater

12

Defroster nozzle

1

6

control

case

core

R H R H

BE687B

Fig BE 45 Heater comtruction

BE 26

Body Electrical System of the heater is control

Operation led by

two

control levers located

on

the instrument panel and a hand op erated knob on the center of the heater unit The AIR LEVER controls the air intake valve and lever

operation of the fan motor When the lever is in the OFF position the water cock is

flow into heater

closed and the circulation of

tion

engine coolant through the heater core stops When the lever is slided to any other position than OFF

control

To

fan motor opera

pull the lever knob Two are for the fan motor provided speeds by using a three position switch

the water

air intake

valve draws the fresh

push

or

FUSE

IOfF

outside air from the cowl top grille and supplies the air into the heater

1

unit The room valve is located at the bottom of the heater unit The air

to the

room

valve where the air is

f

distributed to the floor outlet and defroster

outlets

position of the

depending

room

on

or

the

valve

is

directly linked valve which provides fresh

The VENT KNOB is to the vent

air for the passenger Push the knob all

the way in to open the valve The fresh ventilating air comes out of the heater

rl

FUSIBlE LINK

BATTERY

G

HEATER

UlwlHI

t

ON SWITCH

coming through the air intake valve opening is forced through the heater core

core

the

through the control cables

ROOM The

OFF

positions

valve by its DEFROST and

or room

cock opens in proportion to the lever setting and allow engine coolant to

the heater unit and the other for the

u

HEATE R SWITCH

luJ MOTOR

center outlet

The

TEMP

lever

is

H EATER

dual pur is for regulating the a

pose control one flow of engine coolant flowing into

UN IT

BE868A

Fig BE 46 Circuit diagram of heater

8E 27

Body Electrical System AIRFLOW

OFF

VENTILATING

Vent valve

Push Heater

core

c

IUl

J

n NlL fAl

e

u

c

Push

u

g

Pull

DEFROSTING

VENTILATING

HEATING

Pull Push

J

tTIlsl

0

IU

lI

g IIt

D

WI

I

L

I

Pull

DEFROSTING

Pull

HEATING

IU

I

n

C n

HU

J 11

Pull

UIUI

ff

J CIl

C

JIlT Ill

Pull BE397

Fig BE 47 Airflow

8E 28

Body Electrical System 2

UNIT ASSEMBLY

HEATER

Disconnect three lead wires from

each connector 3

Removal

Remove

front of radio

ground

L

Disconnect battery

2 3

Drain engine coolant Remove defroster hoses

4

Remove and

clips

three

cable

4

cable

retaining

5

cables BE869A

fan motor lead

Fig BE 48 Removing front

cov

r

Disconnect two resistor lead wires

from each connector core

Remove

Withdraw heater

core

from heater

two

retaining bolts and

heater control assembly 6 Install control assembly in the sequence

connecting control cock

S

Disconnect water hoses from

7

the

Remove heater control knobs and

reverse

wires from each connector

6

from

instructions

heater bezel

disconnect control

Disconnect two

bezel

following

in steps I to 3 in Removal of Radio

from valves and water cock 5

plug

radio

adjust

of removal

When

cables to valves and

control

cable

length

as

outlined in Adjustment

housing

and water cock 8

three

Remove

mounting

housing

heater

bolts and dismount heater

unit from vehicle

ADJUSTMENT AIR lever L

Installation

Fig

unit

securing bolts

2

Install water hoses

3

Position heater control cables to

room

BE870A

and install three heater

panel

6

valve air intake valve and water

DEF

air intake valve and connect

control cable to air intake valve

Position heater unit under instru

1

ment

AIR lever to the

Move

position 2 Open

BE 49 Removing heater

Install heater

core

core

3

Clip

control cable with cable

re

taining clip

in the reverse

sequence of removal

cock

Adjust control cable length for as outlined in Adjust proper operation 4

FAN

MOTOR

ment

Connect

5

resistance

fan

wires

wires

motor to

and

from vehicle

Install defroster hoses

6

Connect battery ground cable Fill cooling systeIT

7 8

Run engine

AIR

lever

Make

sure

at

in the that

2 000 rpm with

HOT

position

engine coolant

is fIlled

as

outlined in Removal of

Heater Unit Assembly

Fig BE 50 A iT intake valve

spring clips disassemble heater housing 2

Remove

3

Remove fan from fan motor

4

Remove

S stall

nine

fan

motor

and

retaining

4

Assemble heater housing and in heater unit to vehicle in the

Pull

room

valve upward and

con

nect control cable to room valve 5

and fan motor

screws

up to correct level

heater unit assembly

Dismount

L

plug

9

Removal and Installation

each connector

Clip

control cable with cable

re

taining clip

sequence of removal as out lined in Installation of Heater Unit reverse

Assembly

I

HEATER CORE

Removal and installation CONTROL ASSEMBLY

L

Drain engine coolant

2

Remove defroster hoses

3

Disconnect water hoses from inlet

and outlet pipes of heater core 4

Remove

cover

four

clips

and

Removal and Installation I

front

clips

Remove

and

three

disconnect

from valves and cock

BE 29

cable

retaining

control

BE871A

cables

Fig

BE 51

Room valve

Body Electrical System TEMP lever 1

2

Move TEMP lever

to

the

RG

The red with green wire must

OFF

flat

position 2

3

of water ock when water cock lever is pulled forward fully closed 3

cable

control

on

stripe

lead

connected

to

terminal at back of

combination meter

Connect control cable to the lever

Install

plate

be

B

The black lead wire must be connected to

T

shaped

ter

minal at back of combination

water

meter

cock bracket with cable retaining clip 4

YR

The yellow

with red stripe

lead wire must be connected

BE872A

Fig BE 52 Water cock

pole

to

terminal at back of

combination meter SPECIFICATIONS 6 Item

General

Extremely cold

use

weather

Pass

grommet

tachllmeter on

and connect

use

wires

through

hood lock control wire to

negative terminal of

ignition coil FAN MOTOR

Notes

Rated power consumption Revolution

12V less than 36W 3 600

rpm

Fix grommet with

a

12V less than SSW

or a

2 SOO

an

adhesive tape

sealing compound leakage

to

prevent

water

Fan dia

mm

in

110 433

110

33 4

b Attach tachometer wires to hood lock control wire with

3

TACHOMETER The

is

tachometer

model HL620 It is

an

optional

ignition system It counts pulses entering the ignition coil

are

connected

to combination meter and tachometer on

integral part

the

They

of

cable 4

remove

tions

5

BULB REPLACEMENT

Remove

the and

indicates the number of engine revolu

three

screws

and then I

tachometer from cluster lid

Install in

moval note the

When

sequence of re connecting lead wire

reverse

REPLACEMENT

1 BW

2

following

The black with white

striped

Remove battery ground cable

lead wire must be connected

2

Remve

to

following

instructions iri steps I to 4 of Removal in Combination Meter

identically

chometer cable

colored

coming engine compartment

ta

from

as

previously

Twist illumination bulh socket at

back of tachometer

I

lid

Remove tachometer

described

can

cluster

adhesive

tape

Disconnect four tachometer lead

wire connectors

an

Bulb with socket

then be easily removed

3

Remove bulb

4

Install

new

bulb in

reverse

se

quence of removal Bulb wattage Tachometer illumination

lamp

3 4W

BE965

Fig BE 53 Tachometer BE 30

Electrical

Body the

to

SEAT BELT WARNING SYSTEM

lamp zer

the

lamp to

ignition switch is turned position the warning

ON

on

comes

8

seconds

and remains The

on

sounds if the driver

s

seat belt is

warning

tion switch

sounds for 4 to 8 seconds intermittent

ly if the driver s seat belt is not fastened properly The seat belt warning system con sists of a driver s belt switch a warning buzzer a warning lamp a timer unit and an ignition switch

on

instru

Remove cluster lid Disconnect lead

wire at connee

tor Remove

two

retaining

screws


reverse se

quence of removal


Ignition switch Refer to page BE 22 for Removal and Installation WARNING LAMP BULB REPLACEMENT

Timer unit is fIXed switch is turned

I 2

4

For Canada

ignition

is located

lamp body

Timer unit

When the

Warning lamp panel

ment

3

for 4

buzzer

Warning lamp body

and the warning buz

properly The seat belt warning system con sists of a driver s belt switch a warning buzzer a warning lamp and an igni

Except Canada When the

the warning

position

comes on

not fastened

DESCRIPTION

to

ON

System

ment behind

glove

on a

reinforce

box

I

Remove cluster lid

2

Twist

with bulb

Socket

socket

lamp

warning

then be taken

can

out 3

Pick up bulb from socket

4

Install

new

bulb in the

reverse

sequence of removal Bulb wattage Seat belt

I 7W

warning lamp

INSPECTION

Warning buzzer Apply BE282B

BE688B

Fig BE 54 Timer unit I

Disconnect

CD

sounds

12V direct current between

@

and

or

The buzzer must sound when


@

2

Remove glove box

and

3

Disconnect timer unit connector

circuit See

4

Remove

buzzer

timer

unit

two

on

retaining

screws

reinforcement

can

S

Installation

is in the

Note

is

fIxed

on a

re

BE967A

inforcement behind glove box Refer to the

power

55 for

warning

Make

sure

that

negative

Timer unit

Warning buzzer buzzer

Figure BE

CD

to

terminal of power circuit is always connected to @ terminal

reverse se

quence of removal

Warning

connected

are

Timer

then be taken out

unit

and check whether buzzer

not

preceding

for Removal and Installation

s

ignition key

to

the

ON

Fig BE 55 Warning buzzer

position The voltage between @ and ground must be 12V for 4 to 8

seat belt switch

seconds and then go out See

timer unit

Driver

Turn

Figures

BE 54 and BE 56 I

Remove seat belt

2

Disconnect belt switch lead wire

ecuring bolt Belt switch

at connector 3 4

Seat belt

can

Installation

then be taken out

is in the

quence ofremoval

BE 31

reverse se

Test continuity between two lead wires from seat belt switch with ohm meter or test

lamp

Body Electrical System Circuit diagram of seat belt warning

system

Non California modela except for Canada FUSE lOA

FUSIBLE LINK p

c

DRIVER S

o

@

BATTERY

@I

f

IGNITION SWITCH

BELT

TIMER UNIT

I@

SWITCH

9

I

WARNING

fS

LAMP

2 l

BUZZER

California modela

IGNITION RELAY FUSIBLE LINK

F

lC 1 1

9

FUSE lOA

ORIVE R S BELT SWITCH

BATTERY

f

9

IGNITION SWITCH

WARNING LAMP

r i J 2 I

BUZZER

Canada modela DRIVER S

FUSIBLE

BELT

FUSE

LINK

lOA

aP

o BATTERY

f

SWITCH

9

c

N IGN ITION SWITCH

WARNING

fS

LAMP

J 2 I

Cf

BUZZER

BE689B

Fig BE 56 Circuit diagram of seat belt warning system BE 32

Electrical

Body

System

TROUBLE DIAGNOSES AND CORRECTIONS HORN Condition Horn does not

operate

Probable

Corrective action

cause

Discharged battery Measure specific gravity of electrolyte

Recharge

Burnt fuse

Correct

Faulty horn button contact

Repair horn button

Horn sounds grounded

when horn

relay terminal

s

replace battery

cause

and replace fuse

is

Inoperative horn relay Horn sounds when

or

Replace horn relay

B

and

H

horn

relay

connected with a test lead

tenninals

are

Damaged

horn

or

loose horn terminal

con

nection

Correct horn te

inal

Horn sounds

Short circuited

continuously

button lead wire

When light

horn

button

and

or

horn

Repair horn button

green lead wire is disconnected

from horn relay terminal

s

horn stops to

sound

Inoperative

Reduced volume and

or

tone

quality

Loose

or

onnection

horn

horn

Replace

relay

poor connector contact or horn button

Repair

Fuse relay horn and

Damaged horn

Replace

BE 33

horn

relay

or

its

wiring

or

replace

Body Electrical System WINDSHIELD WIPER AND WASHER

Condition

Probable

Windshield wiper motor does not

Correct

Burnt fuse

cause

and replace fuse

Replace wiper

Damaged motor Check wiper motor

operate

Corrective action

cause

as outlined in

motor

Inspec

tion

Repair

Loose connection and washer switch

Faulty wiper

Replace

Test continuity through switch in

is too slow

Damaged Loose Seized

or

or

circuit

Wiper motor

continues

ground circuit

on

on

motor

Lubricate in

windshield glass

and operate wiper without load

replace

Clean windshield glass and

Damaged

Replace

motor

Remove

stop operation

stop device

auto

to run after switch

relay

is turned off or

Clean dirty contacts bending if necessary

wiper

blades do not return to correct

position

replace wiper

cover

and check

contacts

Poor connection

Repair

Faulty switch

Replace

BE 34

or

blade

Replace

auto

or

wiper blade

Faulty wiper switch

Faulty

motor

Repair

rusted wiper linkage

arm

Repair

Replace

poor connection

Wiper blades stick Raise

or

motor

Humming occurs operating cycle

Wiper speed cannot be changed correctly

outlined

Inspection

Open power Wiper operating speed

as

or

repair relay plate

Body

Electrical

System

RADIO Noise prevention Position vehicle in

an

open

area

control to maximum and set dial at

away from steel a

buildings

run

Condition

Probable

antenna to its maximum

engine extend

medium point without catching broadcasting

length

set volume

wave

Corrective action

cause

Ignition system Noise

occurs

is

when engine

op

High

tension wire

Install

new

Install

a

high

tension wire

erated

Ignition coil

0

51lF capacitor

primary side

to

terminal of ignition coil Be careful not to install capacitor to secondary or primary breaker side other wise engine becomes improper

Note

Install bond strap Distributor

Secure contact of carbon electric

pole

and

rotor

Eliminate sharp tip

on rotor pole or cap pole by scrubbing with a screwdriver Check stagger between rotor and stator

Charging system Sound of alternating current pre

Alternator

Install

0

a

51lF capacitor

to

charging

termi

nalA

sents

Note

Do not use a

larger capacitor

If capacitor is installed to terminal F alternator coil will be damaged When accelerator or

pedal

is

depressed

Install

Regulator

0

a

51lF capacitor

IGN

to

terminal

of voltage regulator

released noise presents

Supplement equipment When engine starts

noise

presents

Noise still presents even after

stop

Operative

noise of water tem

Install O IIlF capacitor between terminal and

perature and fuel gauges

ground

ping engine

Note

wire

If

a

is used

capacitor having

a

larger capacity

indication of gauge will be de

viated

b Cut lead wire

Notes a

Be sure to locate as

to

noise

parallel

capacitor

source

as

close

and connect in

c

as

short

as

possible

Ground wire should be attached the body

d Make

on

completely

installation

35 BE

and connection

e

securely Carefully identify or

OUT

mark

IN

to o Q

m r0 C

i

Ql

1

CIl

Il l3

@

@

D

v

only

models H

L 2

lamp

B

L

type

lamp

marker combinat check headl mp

conetr

U

C a l i f o r n a Californa

models

olenoid

distrbuo

California Non

To

To To To

37

38 39 40

cut

L

Low High sido front horn horn

D D C B

To To To To To To To

resi tor only and tcrminal only coil coil models block igniton condesr igniton Californa only models

30 3t 32 33 34 3S 36

only

models

n

California Non

R

2

lamp

2

n

1

type type

No

lamp

c o m b i n a t marker batery fusible engine altern o headlmp headlmp H

link

1

R

harnes

R

front

transmiter

B

R

side

California Non

solenid

heater cut solen id only cut choke

IS 16 17 18

1

20

1

L

D

ground thermal distrbuo models fuel auto headl mp D

C 8

To To To To To To To To To To To To 9

type R

22 23 i4 is 26

To To To

27 28 29

only

Can da only modeb models for

lamp I

j

except

relay

CCaliforna aliforna only

only harnes amplifer heater counter model relay relay relay models switch compart en mot r relay senor lamp relay regulator cable tinstrumen ransitor ho d washer igniton floor inhbitor voltage T

A

@

dri

e

engine det cor To To Californ a To To To To cauthokoe

full

To

1

2

3 4

S

head horn

Califunia Non

67

89

10 II 12 13 14

OJ m

ll0 ll

CDm

Cl

co ler

To To To To To To To

n

e

g t

OJ

l3 c

oZ l tl

lTI 6o

III

only

ifornia

18 6

@

r

A L

@ f

ca Non

l8

@

DE1A

jB

@

onlY

@

U

Califotl a

a

AIL

DEI

0

11 6 1 1

9

@

13

@ BY

omY

ornta

@

i

ca on l

B

O onlY 0

@

DE1AIL

@

otnia

tll

calit on t

l too i1 l

@

OJ

8il

m

OQ

CIl

II D 3

I

OJ o Q

I

HARNES

J

n

L

ENGt E RO M TO

cf w

0

r

AlT

AfT

solenid

switch

Kickdown Inhibtor Oip

1

cable slinger cable Oip

Engine Batery Engine Batery

23 45678

m

ii bll

m

l

if

3i

to o c

O Dl

I

lti 3

r LB

solenid Transmi o switch Tranmiso switch Transmi o switch mot r harrnoesm Transmi o harrnoesm Transmi o kicdown Automaic rev se Manual inhbitor Automaic presu stare engine Manual engine Automaic

BY

RB 1 BW RB

CJ

BY

B

RB

m r0 O

WB @

RB@RB

YB

oil

2

RB

To fOT To for To for To To To for To for

Automaic Transmi o

B

YB

1

For

Manual For

Transmio

2

3

4 56

7

fBYB RB

BY

BY

stripe

stripe red

white with with gre n

gre n

Transmio

CODE Black Brown Gre n Blue Light Red White Yelow Black Light

COL R

B

BI

G

L

Lg

R

W Y

LgR

BW

Automaic

For

LB

Automaic Transmio

For

B

Transmio Manual For

m

to l0c

mW D

l

s

Q3

Jo Q o

m CD

n Ql

en

I i3

@

I 1

1 I

I

lL

flll I

J

peratuJe

ilumnato

lamp

switch

r

lamp floor

ilumnato

light

Olodels

lamp

te

ilumnato

warni g models R

S

U

timer

only AfT

I

E

IT

U

California Non

L

I

U

comparten

lamp switch switch lighter control control and models control warni g harnes mot r switch harnes wiper wiper cigar heater radio heater belt heater buz er belt indcator co ler wiptr door engine floor

j

II

H R

G

1

harnes

A

or

I

To

lamp To To To To To To

19

20 21 22 23 24 25

Californa

To To To To To To To To To

26 27 28 29 30 31 32 33 34

L @

U@

rL

Can da

Qj

for

switch

except onlAfTy rheosta mode15 met r switch switch control unit

only instrumen d i m e r flasher lamp switch and conetr Jamp switch brake mot r ro m light fuse tachomet r haz rd stop igniton haz rd check AMP CNonaliforna flasher kic down hand heater

cable

clock unit or

switch switch

T

M

tU

@

combinat combinat

To To To To To To To To To To To To 1

2345 6789

10 11 11

ilumnato

To To To To To To 13 14 IS 16 17 18

m

tot lQ

mJ c

E

S

CD o c

m

o

O II

fJl

13

engine J l

To

YA

comparten harnes

IIY Lt

r

wRfl

G

oIll R G

RY ll

L

Ri l

LIB

G

A

GL

only

L

T A

B

LW

AL

LW B

@

y j onl T

I

BG

Can da California Non

except

Can da

R

M

L

except G

GR

13

california Non

GW L

GL

R

A

GW

ft t It BW

B

4D 4 LR LW t4 LG

@ lD m en

l l ii b

CD m

l

lD

tp o c

TS O l

13

rJl

i

lt L

H R

lamp tarnP

H R

y

s

@

haltl

@ 8

d8 Gt

QR

1ii

ou

switch

lamp

fo 1 To 0

1

To To

L

lamp

harnesS sensor models belt unit marker

instrUment co ler floorCalifornia driver tank

Gt

ll

combinato combinato market amp

e cens

side reat 0

1

i

rear side

to To To 10 9

67 45

10

1

t

8

@

@

J

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Q8 t

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Gt Q

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LQR RB Gt 8

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LQR

8

8

8

CD Q8 t

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Bt c


EMISSION WARNING SYSTEM California models CONTENTS FLOOR TEMPERATURE WARNING SYSTEM

California models

BE 43

DESCRIPTION

WARNING LAMP

43 BE

TROUBLE

44 BE

SHOOTING GUIDE

8E 43

FLOOR

The warning

lamp

also

comes

on

TEMPERATURE

during operation

WARNING SYSTEM California models

permitting inspection of the lamp s condition The lamp goes out after the engine starts

DESCRIPTION The

floor

of the starter motor

4


se

Bulb wattage Floor temperature warning

lamp

Refer to Section EC for details

temperature warning a floor temperature

reverse

quence of removaL

17W

system consists of

sensing switch installed floor

a

floor

on

the vehicle

temperature

floor temperature warning harnesses

relay

lamp

abnormal level

will

come

on

the warning lamp to call the attention of

the driver

Lamp body replacement

a

and

When the floor temperature rises to an

WARNING LAMP Bulb replacement I

2

Remove cluster lid Twist

ng warni

Socket with bulb

can

Remove cluster lld

Disconnect lead wire at

connee

tor

lamp

socket

then be taken

out

3

I 2

3

4

Pick up bulb from socket

Remove

two

screws

retaining

lamp body Installation

is in the

reverse se

quence of removal

IGNITION RELAY FUSIBLE LINK

I

P

i

I

l

IGNITION BATTERY

SWITCH

FLOOR

SENSOR RELAY

f

I

I

I

FLOOR SENSOR ON

FLOOR TEMPERATURE

WARNING LAMP

LOW OFF

FLOOR

TEMPERATURE HIGH 7

BE697B

Fig BE 64 Circuit diagram of floor temperature warning system 43 BE

Body Electrical System TROUBLE

SHOOTING

GUIDE

Condition

Warning lamp does not light in START posi tion of ignition switch

Probable

Corrective action

cause

Burnt or loose bulb

Replace bulb

Faulty f1o

Conduct

r

temperature relay

or

correct bulb socket

continuity test

and

repair

place Refer Loose connection

or

open circuit

44 BE

to

Section EC

Check wiring and

or

repair if necessary

or

reo

SE B V I C E I M A N IuI A71i 1

SECTION AC

W

c

i

L

AIR

CONDITIONING


lmSSANJ NISSAN MOTOR CO TOKYO

LTD JAPAN

DESCRIPTION

AC 2

TROUBLE DIAGNOSES AND CORRECTION

AC 19


AC 25

COMPRESSOR

AC 33


AC 39

Air

Conditioning

DESCRIPTION CONTENTS OUTLINE

OF

AIR

CONDITIONER

AC 2

DESCRIPTION

AC 5

AC3

MAIN

AC 7

CONDENSER

AC 3

FAN

COMPRESSOR

AC3

THERMO SWITCH

RECEIVER

AC4

PRESSURE SWITCH

AC 7

AC4

COMPRESSOR

AC 7

AC 5

F I C D

REFRIGERATION SYSTEM

COOLING

DRYER UNIT

ELECTRICAL

CIRCUIT

OUTLINE OF AIR CONDITIONER The

sentially

of

condenser The three

conditioner

air a

cooling

receiver

cooling brackets

location

ment

consists

es

unit is

a

occupied by panel

secured

ttached the

to

with the

package tray

The compressor

air

directed into the passenger compart

I

5

2

6

Cooling unit Expansion valve 3 Receiver dryer 4

Comressor

three outlets at the

serves

to compress

vaporized refrigerant and is attach ed through the bracket to the loca tion occupied by the mechanical fuel pump on the engine sed

refrigerant

AC 7

RELAY VALVE

the

radiator

AC 7

in the

engine compart

ment

The condenser cools the compres

from the duct is

AC 7

SOLENOID

the

in the dash

The cooled

SWITCH

instrument

unit compressor

dryer and piping

through the panel

RELAY

vapor sent

pressor and is located

on

by

the

com

the front of

The

receiver

dryer

serving

reservoir for storage of the

as

liquid

a

sent

by the condenser is located on the right in the engine compartment The piping consists of two flexible hoses

and five copper

tubes which

connect various components of the air

conditioning

system

Condenser Duct

@ Flexible hose @ Copper tube AC724

Fig AC AC 2

1

Cooling system

Air

REFRIGERATION

perature inside the box will drop This is because the alcohol is evaporated

SYSTEM If you were to paint your finger with alcohol your finger would feel cold

This is because the

liquid

alcohol

from

heat away your finger while it evaporates Ifa quickly evapo rating liquid such as alcoliol is placed takes

in

a

container inside

box

a

Conditioning

the

absorbing the

box

the heat from the air insidc

If the

gaseous

alcohol

collected and cooled with cold it will be

changed

absorption of

back into heat

its

a

is

water

liquid by

by the cold

pIe The liquid

refrigerant

the

and then

operates

on

this princi

refrigerant

back to

in

from

dissipated

liquid

a

to

to

a

the outside

refrigerant from a liquid refrigeration system is

changing The

The cooler

is the

The heat inside the passenger compartment is absorbed by changing

water

tem

used

R 12

the

Figure AC

a

gas

by gas

shown

2

f

V7777 High J l gas lLLLLL

I

I

Low pressurt

pressure

1

liquid Low pressure

High pressure liquid

L2

I

gas Inside air

Outside air

U

J6G1 1

t Condenser

i

i

11

t1 I

I

ilill

li

Compressor

J

u

l

i LlJ JJ

r

7

t

qIrJ

U

It

Evaporator

Receiver

J

1

Blower motor

J

f

dryer

L

ttLJ

9

d

lUr I

Expansion

valve AC458

w t

h

Fig AC

CONDENSER The

condenser is installed to

Refrigeration cycle

COMPRESSOR the

front of the radiator The heated and

compressed refrigerant gas from

2

the

compressor condenses to a liquid by being cooled by air passing between the fins of the condenser

compressor is installed to the of the engine and is driven by crank pulley through a belt The refrig The

side

gas leaving the evaporator is forced out to the condenser by com

erant

7

1 GJ

pressor

an

plI

electrical

rpm

is

very

compressed

clutch

Ac459

Fig AC 3 Condenser AC3

force

idling

Because

engine

low during idling

clutch will not d1i 1il

low pressure refrig

to a high gas and high pressure temperature The driving force is transmitted by

vlmnn

iii

and the is

erant

transmit

thus ensuring

the

the driving

smooth engine

Air

Conditioning

AC728

Fig A C 4 Compressor RECEIVER DRYER The pose

The

receiver

amount of the

flowing through the

dryer

of storing the

serves

To

ran ion

e

alve

the system varies with

operating condition

conditioner

the pur

liquid refrigerant liquid refrigerant

To

be

of the

accurate

air the

receiver

dryer stores excess amount of refrigerant when the heat load is lowered It also releases stored ant when additional

cooling

5

From condenser

refriger

FJi c

is needed

i

thus maintaining the optimum flow of refrigerant within the system The

receiver

dryer

strainer and desiccant

includes

They have

1

a

Z

the

job of removing moisture and foreign particles as the refrigerant circulates

i

3

c

I

o

within the system The

pressure

o

switch

is

installed

3

L o

beside sight glass of receiver dryer The

7

W

purpose of the switch is to stop the compressor operation in the event an excessive system pressure builds up on the high pressure lines

R o

r

J J

t

AC230

I

Prc

2

Sight glass

3

Strainer

4

De kcant

surc

switch

Fig AC 5 Receiver dryer

COOLING

The liquid

UNIT

refrigerant

the The

and

rator

the

cooling

cooling motor

and

an

electrical unit a

some

unit includes

an

evapo

expansion valve From the point of view consists

resistor for fan

of

a

blower

speed control

switches and relays

the aid of the evaporator expansion valve Consequently the air drawn

by

the blower motor is cooled

in

passing through the evaporator The expansion valve restricts the liquid refrigerant as it passes through it and delivers sprayed refrigerant to the evaporator for

evaporation 4 AC

evaporates in

with

facilitating refrigerant

Air The

refrigerant within

the

Conditioning

thermo

bulb changes in pressure through the super heat condition of

frigerant gas which

vaporized

re

out of the

comes

evaporator causing the deflection of the diaphragm The lift of the ball attached to the diaphragm is changed by the deflection of the dia phragm thus controlling the amount of refrigerant passing the orifice valve

Diaphragm Orifice Valve ball AC729

4

Sensing bulb Fig A C 6 Expansion value

000 l

1

Motor

8

Resistor

2

Fan

9

3

Lower

case

10

Main relay Thermo switch

4

Cooler duct

II

Cable

5

Evaporator Expansion valve Upper case

12

Cable

13

Harness

6 7

clamp

AC725

Fig AC 7 Cooling unit

ELECTRICAL CIRCUIT

The following wiring diagram pro vides a complete description of the

pressure switch and compressor relay The blower motor fan speed is con

DESCRIPTION

whole circuit

trolled by the fan switch and resistor The solenoid valve is also activated

ignition switch and the fan switch are ON the main relay is When the

The

electrical circuit

of the

air

conditioner consists of four switches two

relays

motor

clutch

and

a a

solenoid valve compressor

a

fan

magnetic

activated flow

causing battery

through

power

to

the fan motor and the

magnetic clutch The magnetic clutch is activated by the thermo switch AC 5

This in turn device

speed

causes

F lC D

the fast idle control to

increase

engine

when the vehicle is at rest with

the engine ON

Air

Conditioning

J c BW BW

00

B

n

B

L

ELECTRIC

L

FUEL PUMP

b@

tl

ILLUMINATION CONTROL

I GL

RHEOSTAT

GL1J

lL

t

m

oB

3

FROM LIGHT SWITCH

ILLUMINATION LAMP

I

J c

I

MAIN RELAY

FAN SWITCH

2 LW

L

fZP I rRL

W

I

FUSE 15A

r

D CJ B J

1

6

1

RY

THERMO SWITCH

COMPRESSOR RELAY

COLOR

I BA

H UE

1 I I

I

i @

IC

PRESSU 1

CODE

B

Black

BW

Black with white

L

Blue

LW

Blue with white stripe

LR

Blue with red

W

White

G

Green

GL

Green with blue stripe

RL

Red with blue

stripe

stripe

stripe

rlTCH IG

D

J oc c G F IC D

m I

SOLENOID

f

LR

COMPRESSOR

FUSE

W

O 0 J ov 0 OVJ

I

t1 n BW

L

IGNITION SWITCH

BW

I IG

AC727

Fig A C B Wiring diagram of air conditioner system AC 6

Conditioning

Air

COMPRESSOR RERAY

MAIN RELAY The

main

cooling

relay

is

located

on

the

unit

tacts in

the

relay

the

electrical power from

When the ignition switch and fan switch are both turned on the COll

supplied

to

closed

are

The compressor relay is attached to

Then

battery

is

the blower motor and the

electrical clutch for the compressor

the receiver dryer bracket

on

the

right

side

of the engine compartment This relay is actuated by the fan switch thermo switch and pressure switch to turn

on

off the

and

compressor

magnetic clutch

1

1

@ Dc

l@

cv

IDe ID

@

@e

L J AC465

Fig A C 9 Main relay

FAN

SWITCH

The fan switch

set

temperature it

serving

as a

control

automatically

switch is

by

the control lever

turns

turned

off When the

off

the

unit is installed on the center console

clutch is turned off

of refrigerant inside the cooling system

speed through used

as

a

main

the

resistor

It is also

relay switch

stopping

2

AC731

magnetic

This switch controls the blower

motor

1

Fig A C 11

the flow

and increasing the cooling system

Pressure switch and compressor relay

tem

perature the

When

determined

air

rises

switch automatically way

to

temperature

the

pre

F I C D

SOLENOID VALVE

the thermo

turns on

the temperature of the air dis

charged from the cooling unit matically controlled as desired

The

In this

is auto

um

to

valve is

at

is ON

supplies

valve

vacu

the F I C D

diaphragm through

hose

connected to the

vacuum

engine engine

The pressure switch is turned off refrigerant pressure in the

solenoid

compartment This the

PRESSURE SWITCH

lC D F

tached to the dash panel in the engine

intake

manifold

when

the

is at idle and the

cooling system thereby raising idle speed to the

predetermined

rpm 800

when

Fig AC I0 Fan switch

cooling system rises to an abnormally This high level 28 kg cm2 398 psi in

turn

The thermo switch is located

on

the

kg cm2

trollever attached to the console box

again

designed that when the

passing through the evaporator cooled down

to

the

341

Thus

is

pressure is

predetermined

s

I

the pressure switch

psi

turns on

air

core

e

pressure in the cooling system When the pressure drops to or below 24

upper side of the cooling unit and is controlled by the cable and the con so

IW

r

compressor

magnetic clutch actuating the com pressor relay and gradually decreasing

THERMO SWITCH

It is

off the

turns

cooling

system refrigerant automatically maintained at

the proper value

at

all times

AC 7

1 AC132

Fig AC 12 F l C D solenoid value

Air

Conditioning

GENERAL SERVICE CONTENTS REFRIGERAiH R 12

AC

8

EVACUATING

COMPRESSOR OIL

AC

8

CHARGING REFRIGERANT

MAINTENANCE

AC

8

CHECKING HALIDE

PERIODIC MAINTENANCE AND SEASON IN

INSPECTION

GENERAL SERVICE

INSTRUCTION

SAFETY PRECAUTIONS

CHARGING

EV ACUATlNG AND HANDLING

SYSTEM

MANIFOLD GAUGE

ELECTRIC

AC15

DETECTOR

LEAK

AC15

DETECTOR

AC

8

AC

8

AC

9

SIGHT GLASS

AC

9

PERFORMANCE TEST

AC

9

AC16

REFRIGERANT LEVEL CHECK

AC 16

AC16 AC 17

COMPRESSOR OIL LEVEL CHECK

AC17

AC10

PERFORMANCE

TEST

AC 17

AC 11

REFRIGERANT

LEAKS

AC18

The

CAN TAP

used

refrigerant

conditioner 12

frigerant

AC 12

the

in

is

generally called

R

12

No other

erant than the above

refrigerant

MAINTENANCE

air

Re

refrig

This in

refrigerant

small

a

it is

case

can

or

PERIODIC MAINTENANCE

liquefied

available In either

high

pressure

season

Refrigerant evaporates easily has

it can abSorb a

of heat

large

Extreme

vaporating

e

must be exercised when

care

the

wherr

amount

handling

refrigerant

periodic maintenance and inspection are most essential

Perform the

following

level

through sight glass

dryer topics

For

details

under

Refrigerant

SUNISO 5GS

or as

Check the entire

2 of

refrigerant

for sign leaks Refer to relative

The

SUNISO

refrigeration

two is allowable

lubricant should

refrigeration

be used to

assure

the successful

than recommended with

other

chemical reaction

viscosity

or

or

oils or

mixing of the would

tacts the air

phere

for

cause

not an

around connection indication that This condition

fittings refrigerant

can

it is is

and

at a

sure

leaking easily

be corrected

by retightening the joints If any joint on line is suspected of small amount of leakage use a leak detector to locate leaking points 3

Check compressor drive belts for proper deflection

lead to lowered

deficient lubrication

The oil absorbs moisture

care

com

Use of oils other

pressor operation

for Leaks

Checking Refrigerant Leaks

as

to expose it

to atmos

extended period of time

tips

following

maintenance

to allow the air conditioner

normally in Keep the entire

to

operate

the

I

system free from

8 AC

at 1 500 rpm

The servicing of the air conditioner only by well

should be carried out trained servicemen

next season

This

chapter

de

scribes essential points of servicing a

Jarge

enter

the

carried

amount of dirt and sand

they

system

will be

refrigerant

with

and may scratch rotating

clog the system or parts This points out the need for care in servicing the system That is disconnecting joints should be carried out in

a

dean

place

Water should not be allowed to get inside the system does

not

However

readily the

The

refrigerant

mix with water

presence of

even a

minute amount of water will cause a

chemical reaction at

high tem produce Since HCl

perature which will in turn

hydrochloric Observe the

compressor for 10 once a month by

c ENERAL SERVICE

acid

hydrochloric

Season off

it con

This points out the need

least

running the engine

Jf

sysiein

If any trace of oil is noted

lubricant

Mixing of the

Level

Check

COMPRESSOR OIL should be used

receiver

refer to relative

topics under

The

refrigerant

on

the

at

INSTRUCTION

checks

Start engine and check

and

351

give

full performance

a

low evaporation point and moreover since the latent heat of the refrigerant

in

Turn

minutes

to enable the air conditioner to

in the container

large

2

INSPECTION Both

usually

under

out of season

should

cylinder

is

a

refrigerant leakage by periodically checking for refrigerant gas leak even

AND SEASON IN

be used

for

LEAKS

LEAK

HANDLING

REFRIGERANT R 12

oil

FOR

AC12 AC 13

HANDLING SERVICE VALVE

DISCHARGING SYSTEM

is

SYSTEM

acid is highly

sive to metals

copper piping corroded and

corro

the aluminum and etc

the

will become

refrigeration

system will become clogged

Conditioning

Air Water

in the system will ice the orifice when the high pressure re is

will

and

obstruct

the

the

of gas

cause

leakage

Before connecting pipes be sure to give coating of compressor oil to the

changed to low pressure refrigerant by expansion valve etc frigerant

be

may

sea

dent than

Therefore

training

importance

it is of first

any other

that

personnel

well trained serviceman should

a

not be allowed to handle the

ting surfaces

refrig

erant

refrigerant

flow

following

The

items

instructions to be

When

I

system line is discon nected plug the opening immediately a

This is especially necessary moisture

to

condensation from

line and

in the

to

keep

out

dust It is also necessary line at

and

prevent

forming dirt and

keep surrounding

above

to

at all

the air

When con

times temperatures necting system lines do not attempt to remove the plug from the opening until ready for immediate use 2 Always keep the working place clean and dry and free from dirt and dust Wipe water off with a clean

Since direct contact of the liquid

refrigerant

with your skin will cause be careful when

frostbite

always

handling or

the refrigerant Wear

piece of cloth

wrap a

3

Have all necessary tools in pre paration beforehand and have tools clean and dry The

oil

compressor

will

easily

absorb moisture when exposed to air Immediateiy close the opening of the container after to observe the

use

It is also necessary

following

notes

your eyes with cool water to raise the

temperature gradually Apply Do not rub your eyes

specialist Always glasses to protect

working refrigerant

oil

from

a

should not be transfused container into another

the failure will

as

possibly cause mois

ture to mix with the oil

b The used oil should not be returned into c

container

a

The oil should not be used if its of

state

is

preservation

not

clear

enough 5

When connecting

or

disconnect

ing pipes from the refrigeration tem

use two

used for

sys

wrenches One wrench is

holding

the fixing

nut

in

place

while the other for turning the mating flare nut Failure to do so may result in

twisted

a

tube

or

may

damage

protec

Consult

wear

your

an

apply

a

or

Should

strikes your body

splash

protective

Also

to the

prior in

to

charging

refrigerant

service

safe strength

dled

container

However

if han

it wili incorrectiy explode always follow the instruc

I ture

Since the condensation tempera of the air is extremely low the air

will not be condensed when

air will

form

for

to

be condensed will be

the volume of the air

to

air

and

in system

a

refrigerant

a

The

hot location

or

drop

refrigerant

it

above S20C

from

a

high

refrigerant

aluminum

copper

hydrochloric

iron

materials in system may be

affect the and

not to

seating surface

gas is heavier than

air and will

lay close to the floor be especially careful when handling it in

generated

HANDLING MANIFOLD GAUGE The pressure at the

on

the seating surface

low

high and

small confined spaces

sides of system should be measured when evacuating and charging refrig

4

erant

The refrigerant itself is nonflam

mable However gas

is

and

special

a

toxic gas

produced when care

phosgene

it contacts fire

is therefore

required

when checking for leaks in the system with a halide torch 5

Do

tern

not steam

clean

especially condenser

on

the sys

since exces

sively high pressure will build up in the system resulting in explosion of the

and when diagnosing trouble in

the system The manifold gauge is used for these purposes A manifold gauge has two pressure gauges a low pressure gauge and a high pressure gauge These

gauges are connected to the high and low side service valves of system

through flexible charging construction

shown in

of

Figure

hoses

manifold

The above in

handling

their strict

are

essential

precautions of Refrigerant l 2 observation requires AC 9

and suffi

and the center

is

is

fully screwed

path

are

path

blocked When

valve stem is backed off the

opened

The

gauge

AC 13

When valve stem

system

give scratches

at connections

other

gas is odorless and

colorless and breathing may become difficult due to the lack of oxygen Since the

and

produced

are

chemical reaction

tions

particular

be

effective

of condenser

The pressure rise will become

When

mixed

area

gas will be red uced and

refrigerant refrigerant gas

2

the

Consequently

thermal transmission

red ueed

and

thus remain in gaseous

acid which will adversely

never

refrigerant

gas is condensed in the condenser

will

the label In

system

refrigerant Air following delete

Therefore on

refriger

new

has the

refrigerant

to

rious effects

2

The

refrigerant

be evacuated from

must

in system

a

caution

into

the valve is front seated and valve

use care

A small scratch

ant

proportional

has

use

When air enters the system all

film

connection

6

During servicing keep air from getting

eye

when

eyes

EVACUATING AND CHARGING SYSTEM

the

goggles

the system

cool water and

on

3

The

a

tive film to the eye to avoid infection

l250F height a

around service

refrigerant should get into your eyes when charging the refrigerant splash

stpre it in

Notes

gloves

valve to protect your fingers against frostbite by refrigerant If any of the

around

cloth

4

SAFETY PRECAUTIONS

observed in

closely

the system

servicing I

general

are

paths

are

Air Conditioning

Low

pressure gauge

Compound

pres

lIrt

c Back

se

High

gaug

7

ure rHe g Uge

I

ted

Full counter clockwise

Ji

Front seated Full clockwise

J

r

gL

rnF

r

rr1

W

t

2

g To

low side

vacuum

refrigerant

rvicc valve

pump

OI

can

To high

ide

service

lve

va

AC243

Fig AC 13 Manifold gauge

HANDLING SERVICE VALVE

Connection to service valve

into

The refrigerant gas wili be since

check

valve

is

discharged when

open onto

pressing charging hose

service

valve 3

loosen the connection fit of charging hose at manifold

Next

ting

to purge gauge side for 2 to 3 seconds air hose inside charging by the any

pressurized

gas in system

Disconnedion from service val v I

Fully close both valves of

mani

fold gauge 2

Disconnect

two

from service valves

charging hoses

At this time

the

gas will be discharged until check valve is closed Therefore disconnect hose

quickly Caution

Work with fingers

with cloth

fant l fri

against

protected

frostbite by

re

valve

When

this valve

the valve is

valve

service

nected to

Remove caps from service valves

Connect high and low pressure charg ing hoses to service valves in system

service

presses against the connection fitting that is when charging hose is con

gauge 2

check valve is built

An automatic

Fully close both valves of mani fold gauge Connect high and low hoses to manifold pressure charging I

When charging hose is discon nected the valve is closed automatical

open

To

ly Always observe

the

following

usage

2

during connection and disconnection of be

using

quickly

while pressing

charging

hose

Caution

valve

cap

hoses

nut

of

service valve

Work with fingers protected against frostbite by re

after 3

build up at the side of system and air low pressure dirt and in In addition may be sucked result enter the valve dust will

gradually

easily

in

flare

frigerant install

When high speed opera tion is per formed without valve cap a negative

ing

against

charging

with cloth

service valve

pressure will

hoses and

refrigerant will forcefully discharged Therefore

charging

connect and disconnect

precautions Always

Check valve will be half opened

foreign

matter

entering

the

Since close contact between the

thread of valve eap and the thread of valve will prevent gas leakage

service

these sections clean and free of

keep

scratches and damage 4

Since

will be lost during long check

packing prior

ing hose

system

of charging hose

packing

to

use always installing charg

J

17

t 1

L

j

Close

1

5V

Open

Fig AC l0

t

Cap

2

Service valve

3

Charging hose AC733

AC 14 Service oolve

Conditioning

Air

HANDLING CAN TAP A

wide

available

variety of

The

can

terclockwise taps

are


up Attach

3

conventional can taps apply For the correct usage refer to the

firmly

manufacturer

wise

to

instructions

s

that

so

the

is

needle

pulled

4

tap

can

Turn

can

tap

to

make

a

to

refrigerant

handle

hole

in

can

fully clock refrigerant

can

5

b r

r

Caution

Use can

tap of good quality

Turn

Connect

I

Fig A C 15 Service value

center

charging hose to the fitting of manifold gauge At

this time

fully

turned in Turn

2

confirm that both stems

are

counter

Refriger

fitting

will

flow up to the of manifold gauge

gas

Loosen the

6

fitting

center

few seconds

front seated tap handle fully

can

coun

handle

fully

ant AC734

the

clockwise to raise the needle

ing

hose

connection

center

a

t

the

of manifold gauge for

purge air inside See Figure AC 16 to

a

charg

Counterclockwise

docK wise

n s

r

r

@

1

Can tap handle

2

Charging

3

Needle

4

Refrigeran t

hose

can

AC246

A

rn air

n

Purging

R

I2 AC247

Fig AC 16 AC

Can tap and pwging air q

Conditioning

Air DISCHARGING SYSTEM

EVACUATING SYSTEM

pressurized refrigerant gas Ul side system must be discharged to a atmospheric pressure approaching pressure prior to evacuating refrigerant

1

The

This operation should permit safe re oval when

inside system be made

to

replacing system components I and low pressure Close high valves of manifold gauge fully 2 Connect two charging hoses of manifold

gauge

to

their

respective

service valves 3

Open

both manifold gauge valves

slightly and slowly discharge refriger ant from system See Figure AC 17

Connect

hoses of manifold gauge to their respective service valves of sys

Do not allow refrigerant to rush

out

be

Otherwise compressor oil will discharged along with re

frigerant

and

tern

d ischarge

Refer

3

Close

utes

from

refrigerant

Discharge System 2 When refrigerant has been dis charged to a pressure approaching at mospheric pressure connect center charging hose to a vacuum pump system

of ascension of the low

rate

less than pressure gauge should be I in Hg in five min 2S mm Hg

low pressure

charging

to

both

valves

of manifold

If the pressure rises

negative pressure there is

the

or

can not

specified

be obtained

leak in the system

a

In this

pump 4 Open low pressure valve and suck old refrigerant from See ystem

immediately charge system with refrigerant and repair the leak de scribed in the following Confirm that both valves of I

Figure AC 18

manifold gauge

Then start

fully

gauge

vacuum

case

fully closed charging

are

S

When low pressure gauge reading

then disconnect center

has

reached

from

mm

Note

and

high

b The

Hg

20 in

pressure valve

approximately 500 slowly open high See Figure AC 19 to

Hg

When pressure inside system has dropped to 710 mm Hg 28 in Hg 6

of valves of manifold

fully close both and stop

gauge

stand it state

for 5

vacuum

pump

10 minutes in this

to

confirm that

and

Let

the reading

in

vacuum

pump

Connect center hose

2

of

place

refrigerant

and hose

vacuum to

can

to

pump

tap Attach

can

tap and

can

pass

to manifold gauge

refrigerant

Loosen the connection of center

3

fitting of manifold gauge

purge air

to

from center hose 4

Open

low pressure valve of mani

does not rise

fold gauge and charge

refrigerant

Notes

system After

about 0 4 kg

a

The low pressure gauge reads lower by 2S mm Hg I in Hg per a 300 m 1 000 ft elevation Perform evacu ation

according

to

the

following

Ib

of

close low pressure valve for refrigerant leakage

Repair any leak Checking for

with a leak detector

found

Refer

Leaks and

to

Refrigerant

Confirm

6

into

I charged

has been

refrigerant

into system 5 Check

ages

table

one can

that

Leaks

both

valves

of

manifold gauge are fully closed and then change center charging hose from Elevation m

0

300

ft

Vacuum of system mm

0

I 000

600 2 000

Hg

Hg

can

tap to

7

Note

Caution

valves and operate

Protect

fingers

the pressure in system has

26

710

low pressure gauge

25

suck

it therefrom AC 12

refrigerant mm

Hg

28

from

in

pump

system

Hg

to

When

dropped to fully close

both valves of manifold gauge The

above

operation completes Next charge system refrigerant Refer to Charging Refrig evacuation

erant

with cloth

vacuum

27

Values show readings of the

against frostbite by refrigerant when connecting the charging hose to the service valve or disconnecting

pump and low pressure

68S

635

Fig AC 17 Discharging system

high

Open

28

7

AC735

vacuum

710

660

900 3 000

in

of

Air

Conditioning

1

j jJ

J

J

lJ

I1

R

i

j

J g

ru

AC736

Fig A C l8 Euacuating system

j

First step

AC737

Fig AC 19 Euacuatingsystem

Second step

CHARGING REFRIGERANT I

Install manifold gauge to system

Refer

to

Manifold

Handling

Gauge Notes Be sure to purge air from the high and low pressure charging hoses b If air is mixed with refrigerant gas a

in system

evacuation of system

should

performed

be

Refer

to

Evacuating System

2

Attach center

manifold

charging

hose

of

refrigerant can through can tap Break seal of refriger ant can to allow refrigerant to enter manifold gauge Loosen charging hose gauge

at the center

and

purge hose Refer

to

fitting

air

AC738

Fig AC 20 Charging refrigerant slow

of manifold gauge

from

water heated

inside charging

about

Handling Can Tap 3 and low pressure Open high valves of manifold gauge and charge

refrigerant

to

into

system

See

Figure

AC 20

immerse

400C

note that

is

temperature of

l040F

However

dangerous when Figure AC 21 R

121

Immerse in water

Under any circumstances the refrig erant can must not be warmed in to a

heated to about

400C 1040F

Note that hot

temperature of

water is

520C l2S0F

b A blow torch

refrigerant charging speed

in

Cautions

over

When

a

can

this is

water heated

a

to

water is hot See

a

Notes

refrigerant

be used to

or

warm

stove must

up the

AC13

can

never

AC252

dangerous

Fit AC 21 Heating refrigerant

Air b When

low pressure

charging hquefied refrigerant

After

into the system lith the can turned

upside time

down it

charge

pressure

to

valve

Conditioning 3

completion

charging

of

the

be turn compressor should always See ed Several times manually

reduce charging

only through high but not through

When

5

he

close

fully

refrigerant

a

Before valve can

refrigerant

can

with

one

new

Figure AC 22

empty

Ives of manifold

both

gauge and replace

is

can

to

be

charging

opening manifold gauge charge refrigerant from new

sure to

purge air from inside

hose

Charge the specified amount of refrigerant into system by weighing charged refrigerant with scale Over charging will cause discharge pressure 6

to

rise

t

Q

UL

v1ifl

j AC739

Fig A C 22 ClUJrging refrigerant First step

4

If refrigerant charging

down

charge

it

speed

slows

Iunning the of charging After

compressor for ease having taken the steps up to 3 above proceed with charging in the following order

Shut off high pressure valve of manifold gauge

I

Caution

Never

back into

while

charge

refrigerant

pressure side of sys tem since this will force refrigerant

through high

may 2

refrigerant explode

Run the engine

can

and

can

idling speeds

at

about 1 500 rpm Set

3 lever

and

the

temperature

fan

switch

at

control

AC255

Measure the amount of charged refrigerant with a scale Make a note of the amount charged from

maximum

can

Fig AC 24 Measuring refrigerant

cool and maximum

speed respectively refrigerant while con

4 Charge trolling low pressure gauge reading at 8 kgfcm2 40 psi or less by turning 2 in

or

out low pressure valve of mani

Refrigerant capacity

fold gauge See Figure AC 23 Unit

Minimum

Refrigerant R 12

Note

0 7

15

lb kg Maximum 0 9 2 0

presence of bubbles in glass of receiver dryer is an

The

sight

unsuitable method of amount

of

system The

checking the refrigerant charged in state of the bubbles in

sight glass should only be used for checking whether the amount of t

AC740

Fig

A C 23 Charging

refrigerant AC 14

Second step

charged refrigerant is small or not The amount of charged refrigerant can be correctly judged by means of discharge pressure Refer to Re frigerant Level Check

Air After

7

the

specified

amount

Conditioning

Refrigerant is a colorless odorless leakage from system is diffi

of

I

Discharge

refrigerant

in

or

one

refrigerant has been charged into sys tem close manifold gauge valves Then

gas and

two seconds to ascertain that system

cult to detect Accordingly the use of leak detector facilitates check for

has

detach

a

charging

valves of system valve cap 8

to

from

hoses Be

sure

to

service

install

checking

with

a

leak detec

tor

Refer

Checking for

to

Two methods of checking

available

service valve

Confirm that there are no leaks in

system by

leaks

employs

one

a

kg I refrigerant if necessary 2 Light leak detector Adjust the height of the ilame between flame

halide leak

detector which burns propane gas or butane gas and the other is an electric

adjusting

type leak detector

of combustion tube 3

Performance Test

when

which Dr

a

leak test whenever leak is

of connection

lines

the

at

top and bottom plate

A reaction

fittings

Place the end of sampling tube the point of the suspected leak in

near

Since the propane leak detector and butane leak detector are the same in

system Notes a

Since

refrigerant

gas is heavier than easily detect

leak detector

air small leaks can b

The copper screen is heated by the burning of propane Refrigerant gas

ed by

decomposes

suspected and conducting service operations are accompanied by disassembly

loosening

HALIDE LEAK DETECTOR

respect to their operation this section describes the operation of the propane

CHECKING FOR LEAKS of refrigerant

with 04

will immediately become red hot

Conducting a performance test prior to removing manifold gauge is ice sen a good operation Refer to

Conduct

needed for

pressure

Charge

of

lb

are

Leaks

Note

age

sufficient

a

leak detection

to

color the flame when it

contacts the heated screen

placing sampling tube direct ly below the check point b Suitable ventilation is

refrigerant

The gas to

be checked is drawn into the sampling

surrounding

tube and

always

sent out

the burner

to

required

is mixed with

gas

If the

air leak detector will

a response and detection of the actual leak will be

A

refrigerant leak can clearly be detected by variations in the color of the flame

indicate

difficult c

Never

bold

at

leak detector

an

angle Cautions a

Never

inhale the fumes produced by combustion of refrigerant gas since they are toxic

b Never

halide torch in

use

where combustible is

present

when there is

no

refrigerant gas being

burned When there is ant gas leak

yellowgreen age is

blue 2

Copper reaction plate Flame adjusting lines

3

Burner

4

Sampling

5

Strainer

AC010

tube

6 Gas bomb 7

Flame

adjuster

Fig A C 25 Checking for leak

Pale blue

SMALL LEAK

Yellow

Bright

burned

I

Or

Compressor Compressor shaft

LARGE LEAK

Purple

Vivid green

seal

rotate the

by hand

plug

Flexible hose connections cover

and side

cover

gaskets

Service valve 2

blue

Since the color of the

purple

will be

Rear Greenish blue

refriger

yellow when dust is there is aging scale on being copper reaction plate always keep the strainer of sampling tube and reaction plate clean 5 Major check points ilame

Butane type

NO LEAK

small

large the ilame will be brilliant

or

Oil filler type

a

the ilame will be green or When refrigerant gas leak

compressor

Propane

place

The ilame will be almost colorless

4

1

a

explosive gas

or

Condenser Condenser pipe fitting Condenser inlet and outlet

pipe

connections

AC 15 I

Air

3

Piping Flared section of

high

pressure and

Conditioning

REFRIGERANT

2

LEVEL CHECK

maximum

low pressure flexible hose

Pipe

connections

SIGHT GLASS

rvice valve 4

Evaporator housing

receiver

Jnlet and outlet pipe connections

ELECTRIC LEAK DETECTOR

through

operational procedures

amount

refer

to

the

3

Set blower

4

Check

maximum speed

to

sight gla

after the lapse

is

to

the

following table

there is enough refrigerant in system is given by observing refrigerant flow

Expansionvalve

for

glass

sight

However

method is unsuitable for

the instructions furnished with

measuring

level

can

judged

be

this

the

correct

t e system pressures in

cordance with the scribed

judging

of refrigerant The

refrigerant

each electric leak detector

procedures

by ac

de

Performance Test

Start the engine and hold engine speed at 1 500 rpm

AC741

I

Amount

to

position

of about five minutes Judge according

provided at the top of dryer One guide for whether

Sight glass

Set temperature control lever

Fig AC 26 Temperature control lever

of

refrigerant

Almost

no

reftigerant

Almost

no

difference

Too much refri crant

Suitable

Insufficient

Check item

Temperature of high pressure and low pressure pipes

between high

pressure and low pressure side

High

pressure

side is

High pressure side

hot and low pressure side is cold

bubbles are seen intervals of 1 2

Almost transparent Bubbles may appear when engine speed is

and

High pressure side is abnormally hot

is

low pressure side is fairly cold warOl

temperature State insightglass

Bubbles flow continu

ousty

Bubbles will

disappeu thing like

a nd some

mist

The at

seconds

conditions

r

I

AC256

High pressure side is abnormally loW

Stop compressor and conduct check

an

M

A

A

Repa ir

seen

No clear difference exists between these two

is nearly gone

Pressure of system

be

can

raised and lowered

will

now when rerrigeran

I

No bubbles

overall

I

II

I

AC258

AC257

and low

Both pressures on high and low pressure sides

are

are

Both pressures on

high

preSure sides slightly low

normal

Both pressures on high and low pressure sides are

abnormally high

Check for gas leakage

Discharge reftgerant

repair as required re plenish and charge

from

system

AC 16

11 10

service valve of

pressure

side

Air and high blower

Notes

The bubbles

a

glass

seen

the sight

through

influenced by the ambient Since the bubbles are

are

temperature hard

show

to

up in

comparatively

low temperatures below 200C 6S0 that

slightly larger amount of refrigerant would be filled if supplied according to the sight glass Be sure to recheck F

it

possible

is

a

the amount when it exceeds 200C In higher temperature the 680F bubbles b

Condit onin j

are

the

When

becomes

dryer

of

pipe

side

the

receiver

considerably cold

2

compressor

2

Stop the engine and discharge refrigerant of system and then remove from the vehicle compressor Remove compressor fIller 3

plug

Drain compressor oil from compres sor oil sump and measure the amount 4 the

Compressor oil is satisfactory if following amount of oil remains in

the compressor

6 the

oz

chips

or

clean oil 5ump with

new

oil

Discard the used oil and fili with same

amount of new oil Add oil if

5

Check for the in the system

Set

6

uring pressure The correct the

in

range ance

by

side

if pressure is within the

For details

at 1 500 rpm

After the air conditioner has been

S

refer

is

Overcharging will show pressure on discharge side

sure

The oil used sor

lubricate compres

to

circulates into system from the oil

sump

while c9mpressor is

The efore

correctly

to

operating com

measure

the amount of oil

pressor oil

flowing

system must be considered If a considerable amount of leakage of to

refrigerant

gas

happens

oil

compressor

is

the

also

27

oil

compressor

pressor

oil

when

or

replacing

any use the

component part of the system

following cilitates I

service

to return

Operate

idling speed

com

procedure

This

fa

oil to compressor

compressor 1 000

rpm

at or

engine below

with controls set for maximum cooling

of

temperature

Measure

ambient

temperature

meter

3 ft away

one

sunlight

Performance Chart

If compressor is inoperative due to faulty compressor or heavy loss of

refrigerant remove compressor and repair as necessary Then pour oil up to correct level and install on engine After above steps have been complet ed

recheck

oil

drain

level

correct level if level is

oil

Notes

The

a

pressure

followi g

will

manner

change in the with changes in

conditions

to

When

excessively high

blower

speed

is

low

dis

charge pressure will drop When the relative humidity of in take air is low discharge pressure will drop

PERFORMANCE TEST The cooling

level

check is unnecessary When checking the level of

grille

the

Measure

Filler plug

considered

completely sealed system When system operates under satisfying the

air at outlet

ard pressure in

leakage of

a

condition

the temperature of dis

Measure

There will be no compressor oil leak age from

side

suction

Check for any abnormalities by comparing the test results with stand

Fig AC

COMPRESSOR OIL LEVEL CHECK

minutes

12

higher

up in

10

about

system pressures at high pres discharge side and low pressure

measure

direct

specified Perform

to

for

operated

from condenser front Be careful not to expose dry buib and wet bulb to

described later

Test

temperature control lever to

and humidity

the

on

maxi

Start the engine and hold engine

11

meas

discharge side amount of refrigerant

lever to

capin

on

system

discharge

be made

control

cool position

10

of refrigerant

amount

can

Handling Manifold

to

fan

Set

charge PERFORMANCE TEST

of the

mum

9

found less than above amount

high

to

Ga uge

speed

other foreign

the hood

Refer

system

the

close

Connect manifold gauge and low side service valves

7 3 to 4

Check the cleanliness of the oil If

the oil contains

material

Open

However

4

max

S5 to 128 gr 5

3

of the

windows

the

Open all fully

doors

to

Residual oil

appear even if the amount of refrig erant is normal In this case the outlet

15

oil

in the receiver the bubbles will

clogged

is

dryer

to

vehicle

easy to show up screen

for 10

speed

minutes in order to return compressor

performance

of the air

conditioner changes considerably with changes in surrounding conditions

Testing correct

must be

performed

method

This

test

whether system is

judge

using is used

The temperature will change in the following manner with changes in conditions When the ambient air is low

the

rectly in checking for problems

Park the vehicle indoors

guide

If the

in the

the

AC 17

reveals that there is any

in system pressure isolate and repair by reference to Trouble Diagnoses and Cor

cause

rections

shade

test

abnormality the

or

temperature

the outlet air temperature

will become low

to

operating cor

and can also be used as a

I

b

Air Condition ing

REFRIGERANT LEAKS If leaks should should not

are

be be

noticeable

repaired

leaky parts

Then

system

filled with refrigerant Do

operate compressor with level

e

loss of compressor oil If system

atmosphere for

has an

been

exposed

to

extended period of

receiver are

in system

refriger

cessively low If this caution is neglected a burnt compressor will result since heavy loss of refrigerant usually indicates heavy ant

time

If leaks To

topics Here is

dryer

slight and

add

no

refrigerant

detect leaks

be replaced

must

fitting has been retightened dis charge refrigerant from system discon

as

nect

refer

necessary to

relative

under

Checking for Leaks how leaks are stopped

I

Check torque on the connection fitting and if too loose tighten to the proper torque Check for gas with a leak detector

2

If leakage

leakage

continues even after

AC 18

the

air is present

the

fittings

and check its seating

face for damage Always replace if damage is slight 3

even

Check compressor oil and add oil

if required 4

Charge

for gas leaks evacuate

refrigerant If

no

and

recheck

leaks are found

and charge system

Air

Conditioning

TROUBLE DIAGNOSES AND CORRECTION CONTENTS COOLING DIAGNOSES

AC19

COMPRESSOR

FUNCTION TEST

AC 20

NOISE

AC 20

BLOWER MOTOR

PERFORMANCE

STANDARD

AC 22

DIAGNOSES

AC23

DIAGNOSES

AC24

DIAGNOSES

AC21

PERFORMANCE TEST DIAGNOSES

COOLING DIAGNOSES

INSUFFICIENT COOLING

I

I Check amount of discharged air

j No or insufficient

IfOK

discharged

air

1 ChecK

Check sight glass for bubbles I

I

I

Many bubbles

I

I

No or few bubbles

If OK

I

Blower stops

I

I Check refrigeration line for leakage Note

blower

I

If there

are too many

bubbles

stop compressor and check for

Refer to test

on

performance

the

following

page

leaks Then evacuate and

Performance test

recharge

system I IfOK

Discharge the system Evacuate and recharge

lfleaks

Repair leaks and recharge

AC 19

Repair cooling

Refer

unit

diagnoses

to

Blower motor

Air

Conditioning

FUNCTION TEST STANDARD PERFORMANCE air conditioner

The

620 has the below

on

TEMPERATURE

the model

acteristics when all systems

are

in

Discharged

Intake In the cabin

performance char

good

Pressure

air

cm2

170

160C 61 OF

30C 37OF

12 kg

ISoC 64OF

50C 4IOF

13

kgcm2

220C 72OF

70C 45OF

15

kg cm2

213

100C SOOF

IS

kg cm2

256 psi

Pressure

suction

psi

condition Compressor pressure is also indicated below

185 psi

N

E

24

j

23 22

270C

SIOF

psi

21 20

19 Note

18

Engine

17

FAN

16

TEMP

1 500 rpm

3 position Cold Max

15 14 13 I

12 u

0 6 0 5 0 40

3 0 2 0 10 20

25

30

35

40

45

Temperature of outside air

REFRIGERANT PRESSURE ENGINE

1

FAN

MAX

TEMP

Fun Cotd

500 rpm 0

a

Oc 35

u Co

Temperature outside

Pressure

25

18

kg cm2

256 psi

1 0

300C S6OF

15

kg cm2

213 psi

2 kg 1

cm2

17 psi

350C 95OF

13

kg cm2

IS5 psi

1 4 kg

cm2

20 psi

400C J05OF

J2

kg cm2

170 psi

16

kg cm2

21 psi

20

IS

20

15

10

5

0

Temperature of dischuge

kg cm2 14 psi

250C 77OF

S 30

discharge

Oc air

AC 20

Air

Conditioning

PERFORMANCE TEST DIAGNOSES Probable

Condition

Discharge a

Both

air too

warm

discharge

sure too

Corrective action

cause

and suction pres

Air

mixed

refrigerant

with

in

Evacuate and

charge system

system

high

Overcharge of refrigerant

Discharge

some

of

refrigerant

or

check cooling

to

correct level

fan

Loose

belt

or

engine

over

system

heating

b

Both

discharge

and suction pres

fan belt

Adjust

dirty condenser fins

Clean exterior surface with water

Obstructed

or

Insufficient

refrigerant charge

Add

filling

of compressor oil

Drain oil and correct oil level

refrigerant

sure too low

c

Discharge pressure

too

high

and

Over

Refer

suction pressure too low

to

Compressor

oil

level

check

d Suction

pressure too

high

and

discharge pressure too low

e

compressor valve

pack

or

ing

Discharge pressure normal and suction pressure too

Damaged

Repair or replace compressor Refer to Compressor

Loose compressor drive belt

Adjust

Clutch

Repair Refer

slippage

to

Compressor

Reinstall sensing bulb correctly to

Faulty expansion valve

keep

high

it

tight

to

pipe

Replace

pressure normal and luction pressure too low

t Discharge

valve strainer

Clogged expansion Water

has

frozen

at

expansion

Clean strainer Evacuate and

charge system

valve

Faulty expansion

g

Suction

pressure

discharge

pressure too

h Both sure

discharge

normal

and

and suction pres

conditioning properly Discharge air or

too cold

a

Discharge

a

and h exist

high

normal

Air

Faults of both

Replace

valve

from

engine

com

Restricted air flow

through

evapo

Air

leaks

Correct sealing

partment is

operating

normal

pressure

normal

suction pressure too low

and

Clean evaporator fins

ratof

Slow blower motor

speed

Check and repair blower motor and

wiring

AC 21

Air

Conditioning

COMPRESSOR DIAGNOSES

I

COMPRESSOR TROUBLE

Turn the compressor dutch wheel

by hand

I

I

j

If OK

Will not turn

I 12V direct current to compressor clutch Then check clutch engagement

Apply

Internal problem in compressor cylinder

Repair

or

replace compressor

I

j

I

If OK

Clutch does

not

engage

I Check

voltage

oflead wire for compressor

Clutch is damaged

on

cooler cable I

Repair

or

replace dutch assembly

I

IfOK

No

voltage

I Internal

problem Repair or replace

in compressor

Check or repair wiring system for compressor clutch

compressor

AC 22

Air

NOISE

NOISY

Conditioning

DIAGNOSES

I

I I

Set fan switch

2

Change

the

on

engine

rpm

frequently

Detect the source of noise I

From cabin

From engine compartment

j

Cooling

unit

j

Check the resonant sound when the engine rpm is

Blower motor makes noise

changed I

Replace

or

repair blower

I

No resonant sound

Compressor

Resonant sound

itself makes noise

Repeat compressor clutch ON and OFF This checking can be performed by changing engine rpm while fan switch is set at ON

Noisy only

when clutch is

Retighten compressor bracket bolt Ifpiping is resonating add clip

engaged

Noisy

when clutch is not engaged

I Check drive belt for slackness

Remove compressor belt then turn compressor

Check for loose compressor mounting bolts

pulley by

I I

If OK

If loose

Compressor Repair

hand

pressor clutch

or

itself makes noise

replace

Retighten

or

compressor

Nl1

adjust

If noise is heard repair

com

Air

Conditioning

BLOWER MOTOR DIAGNOSES

Blower motor inoperative

Check fuse In fuse block fuse

Single

15AW cooling

15A at

unit

I

j mown fuse

IfOK

Check the continuity and

fitting

Replace

offan switch

I

j

I

If

If OK

Connect fan switch

2

Turn the ignition switch ON IG

3

Set fan switch at ON 1 2 or 3

Check the

voltage

to

Voltage

Replace

wiring harness

fan switch

position

grounding

No voltage

I

I

Check the continuity and fitting of resistance

Replace

on

cooling unit

I If OK

I Replace

I

for blower motor

Blue lead wire is poweI source Blue wire with white stripe is for I

I

damaged

I

I

I

I

fuse

blower motor

Ifdamaged

I Replace

resistance

AC 24

main relay

Air

Conditioning

REMOVAL AND INSTALLATION CONTENTS AC 25


AC29

REMOVAL

AC25

INSPECTION

AC29

INSTALLATION

AC26

COMPRESSOR

WIRING

AC 27

MAINTENANCE


AC27

MAIN

INSPECTION

AC 27

COMPRESSOR

FAN

BELT TENSION

ADJUSTMENT

AC31 AC31

FAN

RESISTOR FOR


AC 2B

THERMO SWITCH

INSPECTION

AC 29

DRYER

AND PIPING

SOLENOID

SWITCH

AC32 AC32 AC 32

VALVE

fixing plate high pressure

flexible hoses from compressor

I

Remove

2

Disconnect compressor lead wire

battery

Loosen idler pulley lock nut then bolt

Remove

drive belt from compressor

Y

Notes a

Use two wrenches when disconnect

b

ing pipe joints Plug flexible hose and compressor joint openings immediately after

at connector

adjusting

D C

AC31 FAN

Remove flexible hose

and disconnect low and

REMOVAL

SWITCH

AC 29

5

COMPRESSOR

AC31

RELAY

AC 27

RECEIVER

AC30

RELAY

AC27

I F

AC30

DIAGRAM


COOLING UNIT

3

HARNESS AND COMPONENTS

AC 27

IDLER

PULLEY

WIRING

compressor

pulley

1

L

disconnection to prevent entry of dust moisture laden air etc

AC744

7

Remove four bolts

securing

com

pressor to its bracket Compressor and attachment can now be detached as an

assembly Notes a

AC477

There on

Fig

AC 28 Removing drive belt

Discharge system Refer to Dis charging System under General Service

6

section

to compressor attachment

with Remove bolts

securing fuel

AC 25

tube

total of four bolts two

lower

side

of

compreSsor

Loosen upper bolts and remove lower bolts When removing upper bolts

4

a

upper side of bracket and two

on

Fig AC 29 Disconnecting ftexible hoses from compressor

are

securely one

hold

compressor

hand

b When installing upper bolts bolts

temporarily tighten tighten lower

then

Air

Conditioning

2

5

R C7

c

L

1

PJJ

Compressor Compressor

attachment

2 3

Compressor

bracket

4

AHernator

5

Idler pulley bracket

I AC745

8

Fig AC 31 Removing compressor

INSTALLATION a

J

c

l

i

Flexible hose to compressor

To install compressor reverse the order of removal Observe the follow e trorf 1001 nhlJo vom R

ing in3

used

new

O

blj

llllt l

F 1 aQ

t31 Jt r1tIU

ifm

Cheo

t

oressor l9Wul

CJiJi

fb

necessary

1

I

of

3

l

Ighten

I

l

e

not

210 I d

l11fd

J

7

V

4l di

No

Yl

y j orflexibie use

t

iI f

J remoV Whenever

J

compres r make

t8 C6itiu tUa t st

idie

1rJ

i mV rit and

adjustril

0

immediate

ectioo Servic

F

be su

I

engine

IJgs

remove

r

l

u

re

refrigerant Refer to and Evacuating Charging System under

m

3U llif

then

with

charge

Gen efal

f

1l

before ready for

beJf tension

adjwt

yv

r

9

s

1Y

h r v

For

a

tOoling 1

b

diive

compressor

belt

and

fan belt tensions refer to

Ildlet

cS

Yt WI j

Cheok refrigerant

t

q

if

leakage

neces

iturn

sary correct Wheniiinstallingccomptess

it serWfiPtiffies When

W

l

5

3 42 D

1i6

5

ti WIf nl lL lil g ncn d et botts if l i 1Ttio illpuntinl qqlJ M re fI

11

f

3

ltlod UfO

rt 16

Evacuate cooling system

Lbolts

aGket

r

s

r n al

S

31U VI

ra

Dons 11

irlUI

JIVU

IQ

oriti

o15g fo IbP o20 iil f6i

J

no

qqll

bnM

kldf

rlT

013 5

undeF

HClJI1f

qt ft

910

es

r

2

mpdi x fler ot oldm

1Ilf i Orb m

n

s

bi2

bffik kuanM

Jli oln L il 1o

compressor

Hw f

boc 19 bB1rllo

e

1 Tf

l

d rnl

v

previously

owt

l dlt kg J

efuouiitITof b11 1fasitlult

sam tiiel

Oil capacity

111 0

linpt

fiil

Wheliqli liiAniitg

witlil

6

Tightening torque

rp

9mPr JU

compressor

joints

connecting flexible hose

ssor UI

SlOt

v

a

coat

apD t 2JIUU l1Il 1 0

1n

to

of Hfresh r uOHltl

fl

to aHn lurfaces of 1l11 fs JJ f J PJU Ht UlUJ jJ

AC26

dO

I

iVl 2 i

wl l

Twl n

U l

rt

bnu

f

1

r2

1Z2

gf

ign rb

nojJ

2

Air

IDLER PULLEY FAN

The standard compressor drive belt

between

0 47 in

when

depressed

with thumb pressure midway between the crankshaft and compressor pulleys

ADJUSTMENT

is

and

32 0

BELT TENSION

tension

Conditioning

12

8 and

mm

If necessary turn adjusting bolt to move idler pulley up or down until belt tension is correct

AC766

Fig AC 34 Removing cooling unit cover

Idler

7

pulley

Remove three ducts from cooling

unit Crankshaft pulley

AC480

AC456

Fig AC 32 Adjustment of bolt tension

Note

Be

to loosen

sure

before turning it after

tighten

locking

adjusting bolt adjustment

nut

3

Re

pipes to their proper engine compartment

Connect low and

high

pressure

i

in

positions

j

l 3

INSTALLATION Remove drive belt To before

this

do

loosen

locking

loosening adjusting

nut

bolt Drive

Be

sure

c

Be careful

valve

2

heat

Remove idler pulley from bracket r

J1evM t

jiwT9ff

or king nut llil reverse

rerr oval jldJ

the order

to use two wrenches when

connecting pipe joints b Plug pipe opening immediately after pipe disconnection

belt will then be detached

by

I

Notes

REMOVAL AND

not to break

expansion wrapped with

This valve is

insulating tape

11

AC767

Fig A C 35 Removing cooler ducts

Remove

8

cable from

thermo

switch control

connector

Remove cooling unit and bracket

9 as an

assembly

of

1 t

Jldr J

I

INSPECTiON Oheck idler pulley for smooth rota tion llfHt

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COOLING UNIT

X

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Conditioning

Air

To install cooling unit

11

I

refrigerant leakage if neces repair Refer to Checking for

d Check

reverse


sary

Leaks under General Service Notes a

Apply

coat of fresh compressor

a

sealing surfaces necting pipe joints oil

to

when

COD

Tightening torque Copper tube joint nut High pressure side 2 5 to 3 5 kg m 18 to 25 ft lb

b Use two wrenches when connecting

cooling pipes c

o

Evacuate cooling system chaJge with refrigerant Refer fo

then

Disconnectirt

re

5 to 4 0 kg 2

see

18

3 8 in

I 2 in

Low pressure side

Evacuating and Charging

System under General Service Fig AC 37

sec

tion

m

to 29 ft lb

tion

connector 3


9

00

L 1

Motor

2

Fan

3

Lower case Cooler duct

4

Evaporator Expansion valve Upper case

5 6 7

8 9

Resistor

10

Main relay Thermo switch

11

Cable

12

Cable Harness

3

c

mp

AC725

Fig A C 38 Disassembling cooling unit

I

Remove

connector resistor

bracket and lead wire

main

motor

relay thermo switch etc from cooling

unit

Remove five screws and duct

3

Remove main relay

4

Remove thermo switch Remove

three

screws

springs securing upper

case

Unfasten

and

five case

and outlet pipes

Expansion valve tightening torque

can now

5

8

Remove

motor

and fan

as

evaporator

remove

Notes a

When

installing expansion

evaporator make

pipe Remove

10

36 ft Ib

Peel heat

expansion

valve from evap

proper

To install

reverse

removal AG28

the order of

b

sure

valve

on

that temper

capillary tube is position on outlet side

oensing ature

orator

inlet

kg m

an

insulating tape from ex pansion valve and unfasten clip secur ing expansion valve capillary tube to

lower

fittings securing

cases

separated

9

and rear bracket

6

be

Upper and lower

assembly Also

2

5

7

in its

Apply a coat of fresh compressor oil to sealing surfaces of pipes

Air

Conditioning

Notes

INSPECTION

a

Evaporator

Tightening torque

Apply

a

oil

sealing

to

coat of fresh compressor

surfaces when

Flare nut for copper tube from compressor

con

necting cooling pipes Check evaporator

for

leakage

or

damage If damaged replace

Refer to

Evacuating

and

i8

Checking

refrigerant leakage if neces sary repair Refer to Evacuating and Charging

a

System under General Service

b

When cooler

disconnecting and connecting pipes be sure to use two

wrenches

See

Apply

tion

to

c

To

prevent

due to

I Disconnect battery ground cable

Disconnect battery ground cable Discharge system Refer to Dis

2

2

Discharge system Refer to Dis charging System under General Service

3

pipes

at

charge

joints

clean condenser

not

Always

use

cold water

cooling system then re refrigerant Evacuating and Charging General Service sec

System under

radiator

explosion

with

Refer to and

of

cold compressed air

d Evacuate

Remove radiator grille Remove radiator shroud

5

cooling

or

Drain engine coolant

4

at connector

do

with steam

section

Disconnect compressor lead wire

possibility

con

high pressure within cooling

system

charging System under General Service

section

of fresh compressor

coat

a

oil

sealing surfaces when necting cooler pipes

Condenser

Receiver dryer

to 25 ft lb

Notes

d Check


dryer kg m

sec

tion

RECEIVER DRYER AND PIPING

Disconnect

to receiver

re

2 5 to 3 5

System under General Service

expansion valve If damaged replace

4

then

charge with refrigerant

Check expansion valve for leakage clogging If clogged clean filter in

3

Flare nut for copper tube

Evacuate cooling system

c

to 29 ft Ib

i8

cooling pipes

Expansion valve

or

5 to 4 0 kg m 2

b Use two wrenches when connecting

tion

On automatic transmission models

Check

e

disconnect both torque converter oil

sary

hoses

refrigerant leakage if neces to Checking for

repair Refer

Leaks under General Service Note

While cooling water is hot take precautions against scalding

6

Disconnect two pipes from con denser remove two screws securing

INSPECTION RecelYer dryer Check

condenser Condenser

can now

sec

tion

for

refrigerant leakage

or

damage

be removed

Check

for proper connection of lead wires running to pressure switch two

Fig AC 39 Diaconnecting

Acno

If any component

part

ing pipes

damaged replace

receiver

pressure switch

an

dryer and assembly

coo

as

is found

Notes a

Plug after

Condenser

all

piping joints immediately pipe disconnection to prevent

entry of dust

or

into

dryer

receiver

I

and

moisture laden air air aJOdi

or

tioning system

AC485

b Use two wrenches when dIsconnect

Remove

receiver

dryer

four

Notes a screws

securing

bracket to vehicle body

and detach compressor relay and pres sure switch as an assembly 6

To

piping

install reverse

er

place parts if damaged or leaky 2 Clogged condenser fins or air sages may reduce

receiver

dryer

and


Use two wrenches when disconnect

ing pipe joints b

7

areas

of

with dry

air

Piping

Plug openings immediately disconnecting pipes To install

compressed

pas

cooling efficiency

condenser Clean these

ing cooling pipes 5

Fig AC 40 Removing conden

Check inlet and outlet pipe joints sealing surfaces for damage Re

reverse

removal AC 29

after

the order

Check piping for occurs

of

at

connecting persists

leakage

connections nuts

If leakage

retighten Replace if leakage

Conditioning

Air

WIRING HARNESS AND COMPONENTS WIRING

DIAGRAM

J c BW

BW

k

ii

gg gg

La

FUEL PUMP B

1 liii

J B

i Ii

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ILLUMINATION CONTROL RHEOSTAT

@

GL

FROM

ELECTRIC

LIGHT SWITCH

Id

CJ

L f 8W lW @

rRl

I

FUSE 15A

D CJ B J

1

B

W

I

o

1t Ll1

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THERMO SWITCH

I

I

COLOR CODE

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ao

jblr

11

0

J

mcl

J

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y

B

Black

BW

Black with white stripe

L

Blue

LW

Blue with white

LR

Blue with red stripe

W

White riC O1 GreeMnQ stripe

tll G

WJ1

l J

stripe

GL

Green with blue

RL

Red

ith blue

r

stripe

201011 br

2f

q

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II

JI1

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IGNITION SWITCH

1

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AC727 0I

pi IJC Wi1q

Air When

MAINTENANCE Replace

wiring harness which

any

deteriorated

cracked

is

in

poorly

or

a

Conditioning

12 volt d

points 3 and points I and

4 2

sulated

Always replace

wire with those of

the same diameter

Do not use wire of

c

is

applied

across

continuity between should also exist

CD

@

smaller diameter Where

securely retain clips or tapes so be frayed or worn

00

necessary

ID

ul

I

CDe IDe

JOO

wire harnesses with

they will by vibration that

not

@e

L

Notes a

AC465

Repair or replace any electrical part which is questionable or likely to cause a

short circuit

When disconnecting battery cables always disconnect ground cable be

positive cable Clean battery and terminals before connecting fore

cables then connect

ground Apply a coat and

positive in that

cable

COMPRESSOR RELAY

order

of grease to terminals

prevent rust formation Do not attempt to conduct a con tinuity test with a screwdriver or service tools always use test lead

Inspection Using


a

test

lamp

or

an

ohmmeter

make sure that compressor

Disconnect compressor relay lead

cable

to b

Fig AC 42 Main relay

wires at connector 2

Remove two screws

pressor relay

securing dryer

com

receiver

to

detach compressor relay 3 To install compressor relay verse

and

tacts

close

con

relay con tinuously

Continuity always exists between points 3 and 4 When current flows through points 3 and 4 points 1 and

reo

open

and

flow

2

This causes current to

close

through 1

and 2


wires c

Do

always or

terminals

ground

not

circuits

use

12V

lamp

test

a

circuit tester as

a

when

unloaded

or

open

are

3W

load

MAIN RELAY

v t

iJ

Removal and Installation The main relay is attached to the

cooling

unit

I

Disconnect battery

2

Disconnect main relay lead wires

ground

cable

AC489

Fig

AC

43 Compressor relay

at connector 3

Remove

Refer

to

cooling

Removal

unit

and

assembly

Installation

FAN

SWITCH

under Cooling Unit Remove the

4

relay relay 5

to

cooling

screw

securing

main


unit and detach main

To install main relay

reverse

the

Disconnect

Remove screws

box

order of removal

battery ground cable securing console

1 2

Withdraw

console box forward

and disconnect lead wire connector

Inspection To circuit meter

and 4

check use

a

continuity test

lamp

in

relay

or an ohm

Continuity between points should exist

3

3

Detach switch knob

4

From

remove remove

5

rear

screws

side of console box

securing switch

and

switch

To install fan switch

order of removal AC 31

reverse

the

AC771

Fif AC 44 Removing fan switch

Air 5

Inspection continuiry in fan switch circuit with a test lamp or an ohm Check

Conditioning

Remove

assembly from

resistor

unit Resistor is upper side of cooling inserted into case 6

install

To

resistor

for fan switch

reverse the order of removaL

meter

Inspection I

Fully

move

thermo swirch lever

to COLD 2

Test

between

continuity

minals with

a

test

tamp

or

ter ohm

an

Continuity should exist Dip capillary tube end into water Test continuity between meter 3

Inspection Test

continuity

between

resistor

and fuse

ice ter

minals Continuity should not exist 4 Replace if switch is found dam

aged

F I C D SOLENOID VALVE Removal and installation

I ICD

011

I

2

THERMO SWITCH

3


Tt tt

Disconnect


AC772

3

Fig AC 45 Fan switch

4

Disconnect thermo switch control

Removal and Installation I

Disconnect battery

2

Remove glove box

3

Remove

Disconnect lead wires and

Installation

5

to

under

Remove two

screws

securing sole

noid valve and remove solenoid valve

cooling

unit

Remove thermo switch

Note

ground

3

vacu

tube

cable and lead wires

Capillary

lube

is

fitted

into

groove in cooler unit

cable

cooling unit Refer

and

1

Remove glove box Remove duct from

RESISTOR FOR FAN SWITCH

Removal

Disconnect battery

2 um

2

cable

ground

I

6

To install thermo switch

reverse


Cooling Unit 4

Disconnect resistor lead wires at

connector

AC77 4

Fig

@

AC 48 Removing

lC D F

solenoid valve 4

To install solenoid valve

reverse


Inspection 1 3n I

O sn

I

I

Test

circuit with

AC492

AC773

Fig AC 47 Removing thermo switch

Fig AC 46 Resistor for fan switch

AC 32

lamp

or

an

ohm

on

Run engine at idle and check to be sure that vacuum is present in line between solenoid valve and diaphragm 3

@

test

Turn both fan switch and thermo

switch

00

a

in solenoid valve

meter

2

CD

continuity

Air

Conditioning

COMPRESSOR CONTENTS DESCR IPTIDN

AC33

COMPRESSOR CLUTCH

AC34

SHAFT SEAL ASSEMBLY

AC36

REMOVAL

AC36

REMOVAL

AC34

INSTAllATION

AC36

INSTAllATION

AC34

INSPECTION

AC37

DISASSEMBLY

AC35

ASSEMBLY

AC 35

REMOVAL

AC37

AC35

INSTAllATION

AC37

INSPECTION

CYLINDER

HEAD AND VALVES

AC37

DESCRIPTION Model

CF206

compressor

a

crank

light weight

type with

specially designed

minimum size and on

is

for

use

compact vehicles The compressor crankshaft is driven

by a belt from the crankshaft pulley through the electromagnetic clutch Two pistons positioned in line are actuated by connecting rods coo nected to the crankshaft and

Discharge

suction

valves

are

mounted in the valve liner between the crankcase and As used

a

cylinder

lubricant

head

SUNlSO NO

Simplified

positive lubrication utilizes existing differential

between

suction

5

is

pressure pressure

intake

provide a film of lubricating oil to bearings All internal components have been designed to provide more than adequate lubrica tion to cylinder walls connecting rod bearings and seal assembly The result is improved lubrication lower seal reduced oil pumping temperatures and crankcase to

and

a

reduction in the

number

AC728

Fig AC 49 Sectional view of compressor

of

moving parts

AC33

Air

1

Clutch wheel

2

Snap ring

bearing

3

Clutch wheel assembly

4

Magnet

5 6

Shaft seal assembly Service valve

7

Flange

valve

8

Cylinder head

9

Cylinder

10

O ring

head

t7

gasket

16

Clutch

17

Compressor assembly

13 14

1 LV

I

15

12

1foo 1t

coil

Cylinder gasket Valve plate assembly Base plate gasket Base plate Oring Oil filler plug

11

Conditioning

assembly

AC775

H

@

COMPRESSOR

@

CLUTCH

3

I

most

between

Clearance

and pulley should be 0 016

to

clutch

at all

that

there is

screws

electromagnetic

coil

Coil assembly

can

then be taken out easily

hub

4 to 0 6 0

0 024 in

Loosen four

mounting

likely source of problem is clutch slippage Factors are listed here Exercise ample care The

Fig A C 50 Exploded view of compressor

mm

peripheral

points 2

Make

sure

no

oil

or

AC776

dirt on friction surfaces of clutch disc

and pulley Remove oil

clutch hub

or

Fig AC 51 Remouing bolt

dirt with clean lint free cloth

3

Make

sure

magnetic coil is

that terminal voltage above

at

2 Bolt

5V IO

Then

using

remove

Clutch

clutch

Removing assembly from

cmnkshaft Fig A C 53 Removing magnetic clutch

INSTALLATION

REMOVAL I

Using

Clutch

hold clutch hub wrench

remove

Spanner

Locate the

Wrench the

With suitable socket bolt

correct

housing

retaining clutch

electromagnetic

position

Then

coil at

on

secure

compressor four electro

magnetic coil mounting screws

hub to crankshaft

Tightening torque Electromagnetic

coil mounting

screws

Fig AC 52 Removing clutch AC34

0 7

kg m

1 ft Ib 5

Conditioning

Air

Install the clutch assembly

2

on

the

crankshaft ST02371000

Key should be set on crank shaft before installing clutch assem bly

Note

3

Clutch

Using

Spanner Wrench

With socket wrench

hold clutch hub secure

9

clutch hub securing bolt

Tightening torque Clutch hub securing bolt 5 1

kg

m

II

AC502

clutch

DISASSEMBLY

They

are

Fig A C 57 Installing bearin 2

Remove two snap

1

bearing

AC503

Fig AC 56 Removing V pulley from

ft lb

rings retaining

Using Installer KV99100610 and Stopper ST33061000 press clutch wheel into V pulley 4 Install inner snap ring in groove 3

located inside of

clutch wheel

Install outer snap ring in groove

of V pulley

ASSEMBLY Press bearings into V pulley with Bearing Installer ST02371000 I

of clutch wheel

AC500

Installer

t

Fig AC 54 Removing snap rings

2

Using

Clutch

Wheel

V

pulley

with

Stopper ST33061000 AC504

Remover

KV99100700 and conventional remove

KV99100610 2

puller

bearings

from

Fig AC 58 Installing clutch wheel

clutch wheel

INSPECTION Check

friction surface of clutch

for damage due to excessive heat

grooving due

excessive necessary V KV99100700

pulley

replace

as a

to

slippage

replace

Fig A C 55 Removing clutch wheel bearings

Using

Bearing

4 to 0 6 0

clutch wheel

bly

3

pulley

Remover

ST33061000 press clutch wheel bear ings out from clutch wheel AC 35

Oil

or

assem

dirt

on

friction surfaces of

clutch wheel and V pulley should be cleaned with a clean lint free cloth or suitable solvent Check coil for shorted

or

opened

lead wire Pay particular attention to grounding part of coil If there is no

continuity

0 016 to 0 024 in

If not AC501

3

4

set

and clutch wheel should be mm

If

clutch wheel and

The clearance between V

2

or

coil

replace

electromagnetic

Air

Conditioning 3

jpL

Y

L

i

0

I

I

I

Push seal assembly except carbon over end of shaft with carbon

ring ring

retainer

4

Move seal

on

facing

out

assembly

into

position

shaft

0

Ace07

wft Fig AC 61 Removing s

key

AC506

Fig AC 59 Grounding point of coil

4

Remove seal

1

plate

I

5

If clutch assembly must lie re placed remember that break in opera

Fig AC 64 Inserting wft ass

tion is necessary The break in opera tion consists of engaging and disengag

5

the clutch some tirty times

ing

so

The

yet

tight

of

a

sealing

AC80e

of this

simplified design long lasting

and

5

With the

pull

out seal

Compressor Seal gland and discard

Puller

a

REMOVAL It is recommended that the for shaft seal I

com

Remove

replacement oil filler plug

with D

lugs and be firmly seated in

Install

seal

not

use

a

re

new

D ring in groove of

plate

Note

screwdriver to pry shaft seal from shaft as damage to

Use

refrigeration

oil to make it

adhere to surface 7

Space

seal

around

ance

plate with equal clear and

shaft

insert

cap

screws

shaft may result

ring

6

Discard all parts of the seal includ ing the O ring

b Do

removed from the vehicle

edge driving

tainer

Fig AC 62 Removing seal plate

Notes

pressor be

The indentions in outside

of carbon ring must engage

shaft seal assembley

compressor is

Place carbon ring in ring retainer lapped surface is facing outward

Note

SHAFT SEAL ASSEMBLY

al

mbly

8

and drain the compressor oil

Tighten

these screws

Tightening torque Seal plate securing 0 7 to 1 0 kg

evenly

cap

screws

m

5 to 7 ft Ib

AC809

Fig A C 63 Removing

wft s

eal

Fig AC 60 Removing filler plug 2

Remove clutch

Refer to Com

pressor Clutch Removal 3 Remove shaft key

INSTALLATION

AC811

Fig AC 65 8pcing 01 plate and tightening cap screws

1

Clean shaft and seal cavity with clean lint free cloth 2

Dip seal gland

in clean

oil

refrigerant

9

Install

clutch

Refer

pressor Clutch Installation AC 36

to

Com

Air

Conditioning INSTALLATION

INSPECTION Check for gas leakage

Plug high and

I on

2

as

Valves and valve plates

follows

low pressure

ed

joints

I

compressor with blind caps Connect charging hoses in lines

between manifold gauge and high low pressure service valves Connect refrigerant

can

eration oil

plug

AC813

at head Fig A C 6 7 Removing cylinder

side of compressor to purge air out of compressor 4

shaft

Turn

5

or

6 turns

that

confirm

pressure low pressure

Then

does

not

gauge If indicates a gauge pressure decrease there is a leak Conduct a leak test decrease

on

Under such then install

a

condition

remove

and

bolts Remove

3

valve plate cylinder by prying

from under

of crankcase to be

the

and or

plate

oil to top and bottom valve to be covered by gaskets

areas

head

tapping

which extend

ears

eration

from

valve plate If head and valve

plate

adhere hold

and tap valve plate

head

from head with

parts again

on area

by cylinder gasket 2 Place cylinder gasket in position on cylinder so dowel pins in crankcase go through dowel pin holes in cylinder gasket 3 Apply a thin film of clean refrig

to middle

filler

furnish

covered

and

hose of manifold gauge 3 Open valve of can tap and charge

refrigerant Loosen oil

are

only as a complete assembly Apply a thin film of clean refrig

Do

Note

not

ears

away

soft hammer

a

hit

or

tap head

to

separate head and valve plate be 3use damage to head may result

CYLINDER HEAD AND VALVES Insufficient refrigerant compression

by damaged head valves damaged gasket Prior to servicing the head and valve plate both service valves should be is

likely

to be caused

or

opened

AC816

Fig A C 70 Applying clean refrigeration oil

to free any gas pressure which

may be in the compressor

Fig AC 68 Removing valve plate

REMOVAL I

Remove

and head the

bolts from

flanged

type service valves using Torx Driver Bit

4

When

removing the gaskets

sharp edged

Note

The direction of

flanged type

service valves should be noted for reinstallation

use

a

cylinder gasket ie

semblies

Notes a

Place valve

4

knife

removing head gasket be very careful not to damage machined In

sealing b Do not

reuse

smaller diameter

blies with restrainer are

go

surface

in position discharge valve

plate so

facing

up and

through

over

valve

on as

assem

reed

locating dowel pins

dowel pin holes in valve

plate

gaskets

AC812

Fig AC 66 Removing service valves 2

Remove

the head

the

remaining bolts

AC815

in

Fig A C 69 Removing gasket

AC37

Fig A C 71 Placing valve plate

Air 5

Place head gasket in position

valve

on

dowel

plate pins go through dowel pin holes in gasket 6 Apply a thin film of clean refrig so

eration oil on the machined surface of

cylinder gasket 7

Place

gasket

so

head

which

head

on

matches head

cylinder

head

dowel pins go into dowel pin

8

Apply

Conditioning a

thin fihn of clean

eration oil to service valve

9

refrig

flanges

Place

flange valve O ring in posi tion on cylinder head 10 Place service valves in position on

proper service

or

discharge

screws

valve ports

suction

and insert two longer

through service

pads head valve plate

holes in head

AC 38

valve mountiing and into crank

case

11

Insert

remammg head screws screws until the heads

and run in all make contact

Tightening torque Head and service valve 2 1 to 3 2

15

kg

m

to 23 ft lb

screws

Air

Conditioning

SPECIAL SERVI CE TOOLS For

Tool number

Description

No

tool

use

Unit

name

KV99100700

To

remove

clutch wheel from V

mm

in

pulley

Reference page

or

Figure

No

620

Fig AC

55

620

Fig AC

58

620

Fig AC

56

620

Fig AC

57

on

Clutch wheel remover

BE436

2

KV991006S0

To install clutch wheel into V

pulley

Clutch wheel

38

1 50

1

installer set KV99100610 Installer ST33061000

Stopper BE437

3

ST33061000

To remove clutch wheel

bearing

from V

pulley

Bearing 38

remover

50 1

BE438

4

ST02371000

To install clutch wheel

bearing

into V

pulley

Bearing installer

50

1 96

Co

tJ AC 39

BE439

Air

Conditioning

Tool number

For

Description

No

tool

5

Unit

name

Clutch

use

mm

in

To hold clutch wheel when removing clurch wheel

on

Reference page

or

Figure

Remarks

No

51

620

Fig AC

620

Fig AC 52

126344

620

Fig

AC 63

J 10549

620

Fig

AC 66

124878 1

spanner wrench

BE440

6

Clutch removing

To remove V

pulley from crankshaft

bolt

BE441

7

Compressor seal puller

To remove shaft seal from crankshaft

BE442

8

Torx driver bit

To

remove

flange bolts

124392

B E443

9

Oil

dip

stick

To inspect oil level

620

BE434

40 AC

110545

SECTION SE

SERVICE EQUIPMENT


SERVICE EQUIPMENT

I NISSAN I


LTD JAPAN

SE 2

Service

Equipment

SERVICE EQUIPMENT

GENERAL DESCRI PTION

CLASS

REMARKS

Indicated in this column

Special Tools role

play

in the maintenance

These

are

rate and

important

very

of vehicles

essential to the safe

ftg1lles

in

As

classi

accordance

with

regards special tools which

are

also applicable to models other than

those

Classification of Speciai Tool

accu

ith

dealt

coluITUl

U

inual m

this

those

names

this

other models

speedy servicing

The working times listed in the col RATE TIME in umn under FLAT FLAT RATE

puted

fication

are

based

SCHEDULE the

on

use

are

CLASSIFICATION OF SPECIAL TOOL

com

Classification

of Special

Tools

General

Important

The identification code of mainte nance

betical

tools is made

up of 2

Inspection

I

alpha

and minor

repairs

4

letters and 8 digital figures 11

The heading two letters roughly classify tools or equipment as fol

General

Ill

Special disassembly

lows

and

disassembly

and

assembly

2

5

assembly

3

6

A Important STOOOOOOOO

11

Special Tool

a

Exclusive with no alternative

Tool

b

Parts will be

KVOOOOOOOO

Special

EMOOOOOOOO

Recently established Engine Overhauling

damaged

if

repaired

without special tool

General Gauge

HTOOOOOOOO

Hand Tool

B

General

I

HOW TO READ SPECIAL TOOL LIST

a

b c

Disassembly such

To facilitate

and

assembly as

engine

transmission and differential

a

Machine GGOOOOOOOO

disassembly

111 Special disassembly and assembly

Gauges

c

General

General disassembly such

as

of

exclusive

parts

automatic transmission

and electrical accessories

servicing

b Special work such

Inspection and minor repairs Inspection and maintenance Unit replacement Minor unit disassembly

as

boring

and

welding c

Work very rarely required

APPLIED VEHICLE OR UNIT In this column word

for tools

applicable

All

is

given

to all vehicle mod

els and unit types treated in this manu al for tools applicable only to particu lar

models

models

or

or

unit

units

types

those are

vehicle

indicated

SPECIAL TOOL SET See attached tool list The

is

put

in

newly added tools

this column

shows

for

and body

regard

new

and

through

77 620NA KV00102000

This set is

X

available

other dealers who must go initial preparation SET

NEWLY ADDED

set

designed for

the chassis

of the 620 models without

to their destination

SE 2

SET 3N71B KV0010l000 This set is designed for use on the 3N71B automatic transmission It con sists of the same service tools as those

previously available separately

Service

Equipment

TOOL LIST ENGINE TOOL

Tool Name

Tool Number

ST050 I SODa

tST05011000

ST050 I 2000

Newly added

5

Engine stand assembly Engine

Remarks

Class FIO

B2iO 610 710

S30

stand

Base

ST05260001

Engine attachment

5

610 710

STlOl20000

Cylinder head bolt wrench

2

610 710 S30

STl 0640001

Pivot adjuster

I

610 710 S30

KVIOI039S0

Valve guide

FiO B210 610 710 reamer

STl1081 000

Reamer

12 2

STl1032000

Reamer

8 0

STl1320000

Drift

480 0

mffi

mffi

3

set

in dia

S30

J

0 315 in dia

STll650001

Valve seat cutter set

2

610 710 S30

STl2070000

Valve lifter

5

B210 610 710 S30

STl3030001

Piston pin press stand

2

610 710 S30

STl53 10000

Crankshaft

2

610

KVI01041S0

Crankshaft main bearing cap puller

2

610 710 S30

rear

oil seal drift

KVIOI04110

Crankshaft main bearing puller

STl6512001

Adapter

STl6701001

Adapter

710 S30

STl6610001

Pilot bushing puller

3

610 710 S30

STl7420001

Chain stopper

2

610 710 S30

STl9320000

Oil filter wrench

STl9870000

Air pump test gauge

STl98 10000

Hexagonal wrench

3

FIO

STl9890000

Rotor adapter

2

FIO B210 610 710

STl9900000

Dummy

shaft

2

FIO B210 610

710

STl99 10000

Bearing drift

2

FIO B210 610

710

STl9920000

Rotor stand

2

FIO B210 610 710

STl9930000

Bearing adapter

2

FIO B210

610 710

ST I 9940000

Bearing pressing tool

3

FIO B210

610 710

EM03470000

Piston ring compressor

2

FIO

B210 610 710

S30 FI0 B210 610 710

SE 3

B2iO 610 710

FIO B210 610 710 S30

Service

CHAssis

AND BODY

Equipment

TOOL

Applied No

Tool Name

Tool Number

Ser 17 620NA

Newly

1e vehic or

unit

Class

Remarks

added KYOO 1 02000

Clutch

2

5Tl 66 1000 I

Pilot bushing puller

All

X

3

610 710 530

KV30100200

Clutch aligning bar

All

X

2

610 710 530

5T200500 10

Base plate

All

X

5

B210 610 710 530

5T20050100

Distance piece

All

X

5

B210 610 710 530

5T20050051

5et bolt

All

X

5

B210 610 710 530

5TZ0050240

Diaphragm adjusting

All

X

5

B210 610 710 530

GG943 10000

Flare nut torque wrench

All

X

2

5TZ2360002

DriftC

All

X

2

5T23540000

Fork rod pin punch

All

X

2

5T23800000

Transmission adapter

All

X

5T23810001

5etting plate adapter

All

X

5

530

5T22520000

Wrench

All

X

2

B2iO 530

5T23860000

Counter gear drift

All

X

2

530

KV311 00400

Transmission press stand

All

X

5

530

5T30031000

Bearing puller

All

X

2

KV32101330

Bearing puller

wrench

FIO B210 610 710 530

Manual transmission

3

B21O 530 FIO B210 610 710 530

2

FIO B210 610 710 530

FSSW71B

X

X

FIO B210 610 710 530

2

B21O 530

Differential ST063 I 0000

Diff attachment

All

X

5

610

ST31530000

Drive

All

X

2

B210 610 710 S30

ST3306S001

Diff side bearing

All

X

2

610 S30

All

X

2

610 S30

All

X

2

610

All

X

2

610

pinion flange wrench

ST33051001

Puller

ST3306 I 000

Adapter

ST3090S000

Orive pinion

rear

puller

bearing

inner race

replacer ST30031000

Puller

ST30901000

Base

ST33230000

Diff side bearing drift

ST3194S000

Drive

pinion setting gauge

ST3l941000

Height

5T3l942000

Dummy shaft

ass

y

gauge

SE 4

Service

Equipment

Applied No

Tool Name

Tool Number

ST30611000 ST30613000 ST3062 1000 KV311 00300

4

5

6

7

Drive pinion outer race drift bar

Drive

Solid

unit

pinion

race

outer race

610

X

2

610

X

2

drift adapter

610

X

2

drift adapter

610

X

2

610 710 S30

All

X

2

B21O 610 710 S30

All

X

2

610

All All All

Preload gauge

KV381025S0

Oil seal

Remarks

2

All

punch

ST3127S000

Class

fitting tool

KVOO 102000

X

All

Collar

Drive pinion outer

Newly added

or

ST31970000

Ser 77 620NA

vehicle

Front axle ST35380000

Kingpin bushing drift

All

X

2

HT56802000

Kingpin bushing

All

X

2

ST36070000

Transverse link

All

X

2

ST35390000

Kingpin grease seal drift

All

X

2

ST38020000

Bearing lock

All

X

2

KV40101000

Rear axle stand

All

X

2

B210

ST36230000

Sliding hammer

All

X

5

B210 610 710 S30

HT72480000

Rear axle shaft

All

X

2

B210 610 710 S30

All

X

2

B210 610 710 S30

reamer

bushing replacer

Rear axle nut wrench

bearing puller

610 710 S30

Steering ST2902000 I

Pitman arm

ST27 180001

Steering wheel puller

All

X

2

HT72520000

Ball joint

All

X

2

ST3127S000

Preload gauge

All

X

GG943 10000

Brake pipe torque wrench

All

X

2

B210 610 710 S30

ST08060000

Master Vac oil seal retainer drift

All

X

3

B210 610 710 S30

ST08080000

Master Vac wrench

All

X

3

B210 610 710 S30

puller

remover

FIO B210 610 710 S30 FIO B210 610 710 S30 FlO B210 610 710 S30

Brake

SE 5

Service

Equipment

AUTOMATIC TRANSMISSION TOOL

Applied Tool Number

Tool Name

Transmission

ST2505S001

Oil pressure gauge

ST25 I 60000

Newly Class added

or

ST07870000

Set 3N71B

vehicle unit

stand

All

X

3

set

All

X

I

Torque driver

All

X

3

ST2532000l

Snap ring

All

X

3

ST25420001

Clutch spring compressor

All

X

3

ST25490000

Socket extension

All

X

3

ST2557000l

Hex head extension

All

X

3

ST25580000

Oil pump

All

X

3

ST25850000

case

remover

assembling

gauge

Sliding

hammers

All

X

3

GG930 I 0000

Torque

wrench

All

X

3

HT6 I 000800

Hexagon wrench

All

X

3

HT62350000

Spinner handle

All

X

6

HT69860000

Snap ring

All

X

3

remover

SE 6

Remarks

KVOOlO1OOO

8210 610 710 S30

WIRING DIAGRAM

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LNISSA NISSAN MOTOR CO J

LTD

Tokyo Japan

L

sued

September 1976 070795 Printed in Japan Publication No SM7E 0620liO t

Service Manual Datsun Pick-Up 1977

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